D4 5T - Starting Engine Clutch Oil Capacity Question

I reckon about half a pint, or 300 mils of ATF is what you need, try and flush the old oil and crud out first using the front drain plug and some gas or diesel.

If you can't get a pair of locking pliers to grab that rounded off plug I'd suggest you weld a good nut onto it though I'm always worried about welding around items with bearings, you need to be very careful about where you place your earth lead so as not to have current running through bearing races.

Another option is to use a small grinder or file to create square faces on that plug again.
Good luck
Mike

Mike,

Thanks for your reply. It is in such a weird area to get to. I am pretty sure it rules out the welding chances 😞 I'm on my way to get some better locking pokers...if that doesn't work, I'll try the filing approach.

I wonder if JB Weld would hold? I will definitely replace the plug with a better quality one!!!

Thanks again Mike!!!

Casey

[quote="TheFourthHorseman"]Mike,

Thanks for your reply. It is in such a weird area to get to. I am pretty sure it rules out the welding chances 😞 I'm on my way to get some better locking pokers...if that doesn't work, I'll try the filing approach.

I wonder if JB Weld would hold? I will definitely replace the plug with a better quality one!!!

Thanks again Mike!!!

Casey[/quote]

You will win Casey, just remove that lower engine side cover so you can swing the 10 pound hammer better and give it a few good belts to smarten it's attitude😖mokin:😆

JB Weld will take 24 hours to properly harden and I think you might not get enough adhesion, I'd try a small pipe wrench first, those guys will grab most odd shaped heads.

I used a small auto parts sprayer running off my air compressor with kerosene to shoot at all directions into that clutch compartment to better flush out the old crud from my RD4, it seemed to work OK.
regards
Mike

I got to ask...
Casey, what are locking pokers?

no matter what i tried--heated 3 times, beat on it with a lump hammer, vice grips and a small pipe wrench, i could not get the drain plug 2b7409 out so i over flushed and let the extra flow out the level plug---but my pinion still grinds when i try to engage it. :Cry:

I think I would try a socket on it. Not one of the 8pt ones for square shanks etc, but a regular 1/2 drive socket turned backwards and then put a bolt head in it etc to turn it. Like Mike says, you may need to square it up a bit with a grinder so the socket fits right.

ccjersey,

I hadn't thought about that idea before!!! I will give it a try the next time that I'm out at the Cat.

My top drain plug I think I used 5/8 wrench to loosen and I think the bottom I had to use a 13 mm wrench. I'm assuming that the guys I bought it from were really good at rounding stuff off and filing it back square 😞

Casey, according to Cat Form 10259-1 the clutch of 4G thru 5T D4 holds one pint, the U models hold 5/8 of a quart.