ok i cant get the fill plug out of my zf 5 speed tranny. is there any way else to get the fluid in it so i can get it to a shop that can get the plug out? thought about taking out the top bolt from the pto cover and prying it open enough to get a small funnel in it and add a couple quarts. the plug is boogered up bad and i cant get the housing hot enough to get it out.

 

Take your shifter off, and pour in from the top.

 

how hard is the shifter to get back in the tranny?

 

Must be you don't have a little welder? Sounds like you're gonna have to weld something appropriate to the plug so as it can be removed. Does two things, attaches something can get a bite on and heats the plug up so it will move.

Take it you know for sure its real low or empty? Sure it doesn't have enough in it as it sits for short drive?

Know someone that does have a welder, will bring the welder to it rather then move the truck?

Them little 120v wire feed welders, dang near worth their weight in gold! (Cheap too)

 

i have a spare 2 wheel drive small block zf 5 speed tranny to get a plug from and i just got done putting a clutch in it and did loose some removing tranny from truck, not sure how much.

 

The shifter is not hard to take off and put back, just a ball and socket. There is a spring in there that you DON'T want to loose/drop. Its been a couple years and I don't photographically remember everything, but I think you could take the whole top plate off (8 bolts) and that will take the shifter off, give you a bigger hole, and not have to worry about the spring. Sorry I dont remember how it worked exactly, but I seem to remember there were two pieces you could take off up there, and I know there was a spring involved somewhere (ask me how I know that one...).
If you want to add fluid this is the easiest way. Hell its probably just as easy as adding it to the side fill plug really. At least you can just dump it in.

The transmission case is aluminum, I don't know about the plug, but that would make welding kind of a pain unless you had a tig.

 

well that was like a trip to the doctor for a shot, all hyped up for alot of pain and just got a little pinch lol. so i took the top off the tranny and put 2.5 quarts in, wasnt too bad a job at all

 

I welded nuts to both my fill and drain.