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  #1  
Old 10-18-2013, 07:46 AM
mjkoenig84 mjkoenig84 is offline
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Default Rear differential gear case issues

Hey all,

This is my first post, and I'm in a little bit of a tight spot. My rear differential developed an oil leak, resulting in a low level. So I pull the gear case cover off, removed the factory rtv, cleaned out the case a bit, put new rtv on and reassembled, all in relatively little time. My issue is how to get the new oil in. I have a 04 Ford Ranger, V6, 4WD, and the gear case only has one fill port that I can find. Its on the very top and the plug for it is 1/2". Everything I've found for this says it takes 5.5quarts of oil to fill. At the rate I'm able to squeeze it in, it'll take till the end of time to fill it. I normally wouldn't have an issue with taking the time to do it the easy way (squeezing a 1 quart bottle in with the tappered fill tip), but I need my truck running so I can move into my new house this weekend. I was wondering if anyone came up with a good setup to get over this relatively simple hurdle.
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Old 10-18-2013, 07:51 AM
Logan03CO Logan03CO is offline
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Default Re: Rear differential gear case issues

Quote:
Originally Posted by mjkoenig84 View Post
I normally wouldn't have an issue with taking the time to do it the easy way (squeezing a 1 quart bottle in with the tappered fill tip), but I need my truck running so I can move into my new house this weekend. I was wondering if anyone came up with a good setup to get over this relatively simple hurdle.
LOL

I don't think there is a magical way of filling it - Just cut the majority of the taper off the cap and get to squeezing....never had an issue with it taking very long at all.

General pictures from the 'how-to' (http://www.fordrangerforum.com/engin...ml#post1103599):

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Old 10-18-2013, 07:54 AM
Springtown FX4 Springtown FX4 is offline
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Default Re: Rear differential gear case issues

They sell little pumps for this, i have a red one from oreillys and its like a little bycycle pump one tube in oil other in fill hole and 5 pumps and your done with one quart. Just used it yesterday to do the transfer case good product to have around for 10 bucks
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Old 10-18-2013, 07:59 AM
Logan03CO Logan03CO is offline
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Default Re: Rear differential gear case issues

Quote:
Originally Posted by Springtown FX4 View Post
They sell little pumps for this
That's true - Harbor Freight baby!!!

$5.99

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Old 10-18-2013, 08:02 AM
86indy 86indy is offline
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Get the pump and mine took about 2.5 quarts with 2oz of friction modifier. Pump it till it runs ouf of fill hole then plug it. Hope that helps Oh mines a 8.8 with a limited slip
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Old 10-18-2013, 08:07 AM
Springtown FX4 Springtown FX4 is offline
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Default Re: Rear differential gear case issues

Quote:
Originally Posted by Logan03CO View Post
That's true - Harbor Freight baby!!!

$5.99

Thats the same one! Works great also used it to change out power stearing fluid in res.
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Old 10-18-2013, 08:10 AM
mjkoenig84 mjkoenig84 is offline
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Default Re: Rear differential gear case issues

Thanks for all the prompt help. I actually went out last night around 11pm and bought that same pump at walmart. The problem is,when I plug the hose in at the top, it creates a mostly air tight seal. There is not a different path for the air in the gear case that is being displaced by the oil to go, other than the same fill plug on the top. So it gets some oil in, but most of it started leaking out the side. Also, the the plug I have is on top of the case, and is diffent than the one Logan shows above. It has a regular 1/2" bit on top. I felt around to see if there was a plug on the side, like the one Logan picutred above, but to no avail. I'm at work now, so I guess I'll take a second look (really it will be like my 5th or 6th look) and go from there. I am not the most seasoned automechanic, but I am a Submarine mechanic, and have developed a decent aptitue for getting simple things like this done in confined spaces, which is why this is so frustrating to me.
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Old 10-18-2013, 08:14 AM
86indy 86indy is offline
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Default

Go to an auto parts store they have gear oil pumps that actually screw on to the oil bottle or most oil bottles (not amsoil..thats what I use...) but it gets the job done.
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MODS TO COME: pillar gauges, recover seats, stereo and that it for now ................
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  #9  
Old 10-18-2013, 11:20 AM
Mattygb2128 Mattygb2128 is offline
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Quote:
Originally Posted by 86indy View Post
Go to an auto parts store they have gear oil pumps that actually screw on to the oil bottle or most oil bottles (not amsoil..thats what I use...) but it gets the job done.
x2, advanced has em
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  #10  
Old 10-18-2013, 12:02 PM
johnday johnday is offline
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Default Re: Rear differential gear case issues

Quote:
Originally Posted by Logan03CO View Post
That's true - Harbor Freight baby!!!

$5.99

Slicker than snail snot!! I'm not far from "Herbie Fright" as I speak. I'll be the envy of Barton City when I get back up there!!!!!!!!
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  #11  
Old 10-18-2013, 03:01 PM
Springtown FX4 Springtown FX4 is offline
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Default Re: Rear differential gear case issues

Quote:
Originally Posted by mjkoenig84 View Post
Thanks for all the prompt help. I actually went out last night around 11pm and bought that same pump at walmart. The problem is,when I plug the hose in at the top, it creates a mostly air tight seal. There is not a different path for the air in the gear case that is being displaced by the oil to go, other than the same fill plug on the top. So it gets some oil in, but most of it started leaking out the side. Also, the the plug I have is on top of the case, and is diffent than the one Logan shows above. It has a regular 1/2" bit on top. I felt around to see if there was a plug on the side, like the one Logan picutred above, but to no avail. I'm at work now, so I guess I'll take a second look (really it will be like my 5th or 6th look) and go from there. I am not the most seasoned automechanic, but I am a Submarine mechanic, and have developed a decent aptitue for getting simple things like this done in confined spaces, which is why this is so frustrating to me.
Just use the pump you have, yes that is the only plug on yours its on the top facing toward the front of the truck its just like mine, use a small screw driver or a small piece of tubing shove it in on top of the fill tube at least it will help it vent and your only filling it up to that hole no fuller.
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2003 XLT FX4 Level II
Painted skid plate, Pioneer double din, painted radio bezel/door handles, headlight mod, throttle cable mod, Gibson cat back, afe cold air, 06+ fender badges, Remote start, 06+ mirrors,06+corners, 35W DDM HIDs 4500k head and fog lights,polished alcoas
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  #12  
Old 10-25-2013, 10:30 AM
mjkoenig84 mjkoenig84 is offline
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Default Re: Rear differential gear case issues

So I feel really stupid. I was using the small vent at the top of the gear case in my attempts to fill it. After taking a day break from the job to move into my new house, I went back at it and ended up finding the fill plug on the back side. I don't know how I missed it the first time around. I popped it out with a 3/8" drive ratchet and pumped in the oil no problem.

When I drove it to retest it, the noise persists, but only at low speeds. Once I get above 30 mph it goes away. If I continue to drive for more than 5 min, the noise does not return even when I slow down below 30 mph. Any hints/tips on what could be causing the noise at this point?
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