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Transmission fill check plug size

This is a discussion on Transmission fill check plug size within the General RZR Discussion forums, part of the General RZR category; What size allen (square) is required to correctly remove the various transmission fill/check plugs? Any other fill checks on gearcases that are out of the ...


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Old December 12th, 2010, 12:46 PM
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Transmission fill check plug size

What size allen (square) is required to correctly remove the various transmission fill/check plugs? Any other fill checks on gearcases that are out of the ordinary?

Got the allen, just wondering about the square size....
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Last edited by FunRide; December 12th, 2010 at 01:11 PM.
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Old December 12th, 2010, 03:52 PM
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Re: Transmission fill check plug size

Quote: Originally Posted by FunRide View Post
Got the allen, just wondering about the square size....
Wow, 21 people looked at this nobody knows what size socket to check/fill the various gearcases....I figured it out.

Will post a brief summary for those that may want to do it....fluild volumes, tools, drains, fills.
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Old December 12th, 2010, 04:45 PM
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Re: Transmission fill check plug size

Got mine with just the socket extension.
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Old December 12th, 2010, 05:52 PM
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Re: Transmission fill check plug size

Well, none of the sizes are out of the ordinary.
What one should be aware of, is there are 2 sections of the gearbox/transfer case assembly that have separate sumps.

Front transfer case has 1 drain, 1 fill, AND 1 Level check plug. Thats 3 plugs that have to come out on the front of the trans.
The fill plugs are all big 3/8" drive square plugs. All drain plugs are iirr 12mm(maybe 13mm)socket heads. The 1 separate level check is also a socket head plug, like the drain plugs, iirr.

The gear case has only 1 drain and 1 combination fill/ level check plug.No separate level check plug like the transfer case.

Front diff has a large Allen plug on it. Don't remember exactly if it was 7 or 8 mm, but it was bigger than the 6mm engine drain.
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Old December 12th, 2010, 08:27 PM
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Re: Transmission fill check plug size

Quote: Originally Posted by allcool View Post
Well, none of the sizes are out of the ordinary.
What one should be aware of, is there are 2 sections of the gearbox/transfer case assembly that have separate sumps.

Front transfer case has 1 drain, 1 fill, AND 1 Level check plug. Thats 3 plugs that have to come out on the front of the trans.
The fill plugs are all big 3/8" drive square plugs. All drain plugs are iirr 12mm(maybe 13mm)socket heads. The 1 separate level check is also a socket head plug, like the drain plugs, iirr.

The gear case has only 1 drain and 1 combination fill/ level check plug.No separate level check plug like the transfer case.

Front diff has a large Allen plug on it. Don't remember exactly if it was 7 or 8 mm, but it was bigger than the 6mm engine drain.
Yep, got them All....Thanks.

I did notice that 1/2" is a better fit than 13mm on the drains and 5/16 allen is a perfect fit on the front diff (didn't try metric). Not sure the shop manual calls for.
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