Well awhile ago i was out of town and my zf started going crazy and gears were sticking and it was a mess. so i felt the tranny and it was very hot to the touch. let it cool down for awhile then drove it home. changed the fluid that night but my problem is i couldn't find a fully synthetic Mercon to use, so i had to use cheapo stuff. In the mist of this both fill and drain plugs just happen to be rounded very nicely. Been a few months. nothing happens, then few weeks ago it was making some gear noises so i found some royal purple Full synthetic Mercon, but this time i was not able to get the plugs off. i returned the fluid and the noise goes away. Now.... i have gear noise and all of the gears work except reverse.It just kicks it out and grinds,no matter what i do.

So the question is, could i still have this ZF by getting those plugs off and changing the fluid or buy a rebuild kit and attempt to rebuild it myself?

 

You can try changing the fluid to see if it helps, but sounds to me like it's time for a rebuild.

 

Weld a nut to the plugs so you can get them out.

It could be time for a rebuild or you could have a issue with the shift forks

 

Well couldnt get them off, but i took the shifter off and filled it from the top and drained it from on of the inspection plates, but still reverse wasn't working.

 

Did you try a "bolt-out" type extractor socket on those plugs?

 

vise grips? I can't see the plugs being any tighter than the last guy put them in. they're bathed in trans fluid on the inside at all times, so they can't seize in there that badly...

though with reverse still not working, it sounds like there are more problems than just bad fill/drain plugs...

 

Yeah haha, i dont really care about the drain plugs anymore, got new fluid in it but no changes, so does anyone know about like the shift plates being messed up or something causing this?

 

It sounds to me like the shift forks are worn and aren't engaging the gears completely. Ie...time for a rebuild.