2G AWD Drivetrain Maintenance Questions

[drthorp]

So I have searched the forums for some details about the AWD tranny and diff maintenance and just wanted to clarify some things. First off, she's a '96 GSX MT, with 156K. I've done the timing/water pump job, a full brake overhaul, now its time to change the drivetrain fluids....errrr never done this before and I am just now realizing it. What should I do to each diff? Whats the best way to change the tranny fluids? I have already ordered the recommended fluids for this from STM. Any input is appreciated!

 

[Kryndon]

If you've ordered the correct fluids and quantities, then what you do is the following. Reference the two pictures. There are 6 total bolts that you need to work with.
#1 is Transmission FILL plug. You fill through there until oil starts coming out of the hole slightly. Needs to be on a level surface.
#2 is Transmission DRAIN plug. Drain it while car is level. Check for metal shavings or irregularities in the oil oil.
#3 is Transfer DRAIN plug. Again, level car, drain through there.
#4 is Transfer FILL plug. Like the trans, fill through there until oil starts coming out.
#5 is Differential DRAIN plug.
#6 is Differential FILL plug (hidden behind the torsion bar).

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Now, some tips. When you crack open the drain plugs, crack the fill plugs too so air can get in and let the oil out a bit easier. Use this time to prepare NEW crush washers, and even bolts if you bought those (highly recommended but not obligatory). After the initial fill up of each system, torque all the bolts down and go for a ride around the block. This allows the new oil to get in all the inner bearings and crevices and to coat all the gears. Stop the car again on a level surface and recheck each oil level. Fill until it starts coming out again, but just slightly. Torque everything down. You're all set!

 

[Fyke]

Another tip to add in. Always crack your fill plug open prior to drain plug. Its a bad day to find out you can't get the fill plug open when you've already drained all the fluid out!

 

[Mech Addict]

That hadn't occurred to me until you wrote that, but certainly true. Made me think to add that those plug heads are rather low-profile, so use a wrench or socket that engages well before trying to loosen them. Never know when someone reefed on a breaker bar to stop it from seeping one time, and now it's "on there!". I agree with getting new crush washers, too. Then you're not the one putting a breaker bar on to stop it from seeping.

 

[drthorp]

Very helpful, guys! Ill definitely have to grab some new hardware (I hadn't thought of that). Anyone know a good place to find these new plugs and washers?

 

[drthorp]

https://stmtuned.com/collections/1g...-laser-4g63-transfer-case-seals-rebuild-parts
So do I need both the washers shown here?

 

[Kryndon]

Yep, 3 quantities of each washer. The bolts only need replacement if their heads are too stripped.

 

[drthorp]

Big help guys. Ill update if I end up needing bolts or more help!