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Servicing manual gearbox/xfer case Hilux

Tech Talk for Cruiser owners.

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Servicing manual gearbox/xfer case Hilux

Post by hellfire »

On an 89 Hilux how do you replace oils in gearbox, xfer case and diffs?

If anyone has done this or has pics and tips on how to do this that would be sweet :twisted:
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Post by Sic Lux »

Plug on the bottom of the case and G box 99% of the time will be a 24mm and same on the side of the box and rear of the case there will be a 24mm bolt/bung thats the level to fill it to. Do it when the oil is at operating temp Helps get more of the dirty oil out to put it simply
plenty of parts on the bench
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Post by ferrit »

Pull the filler BEFORE the drain too.... Its bloody difficult to get oil into a gearbox via a hole in the bottom of it! :lol:
2005 HDJ100 Manual, ARB bar, XD9000 winch, ARB rooftop tent + awning, Drawers, Engel, 2" OME lift, 285/75R16 KM2's, iCom, HID XGT's.
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Post by hellfire »

What is the filler lol and where can it be found. Also around how much oil does the gearbox/xfer case take
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Post by ferrit »

Filler on the G52 is about halfway up the side of the box on the passenger side- big 24mm plug.

Gearbox takes under 2L from memory- Just keep filling it till it starts to flow out of the filler hole! :D


Transfer case the filler is about halfway up the side on the rear- where it kicks down to go to the front diff.
2005 HDJ100 Manual, ARB bar, XD9000 winch, ARB rooftop tent + awning, Drawers, Engel, 2" OME lift, 285/75R16 KM2's, iCom, HID XGT's.
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Joined: Fri Apr 04, 2008 5:04 am
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Post by hellfire »

Alright sweet thanks mate
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Post by oldmate »

ferrit wrote:Its bloody difficult to get oil into a gearbox via a hole in the bottom of it! :lol:
You actually tried to fill it that way?
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Post by ferrit »

yeah.... one of the work trucks has a broken off filler plug- all you can see is the mangled end of it melded into the alloy housing by some idiot with a cold chisel... so you have to fill it from the bottom, until oil comes out of the breather, then quickly put the plug in while it tries to all escape.

I suggested putting the truck onto its side with the forklift, but that didnt go down too well! :lol:
2005 HDJ100 Manual, ARB bar, XD9000 winch, ARB rooftop tent + awning, Drawers, Engel, 2" OME lift, 285/75R16 KM2's, iCom, HID XGT's.
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