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Member
- Joined
- Aug 6, 2007
- Messages
- 543
- Reaction score
- 11
- Points
- 18
- Vehicle Year
- 1994
- Make / Model
- Ford
- Engine Size
- 4.0L
- Transmission
- Manual
A while back after swapping a 89 Bronco II from an automatic to a manual, the problem of the shift rail plugs came to our attention when having to add fluid to the transmission every other week. After consulting the tech library, we decided to try the metal plug option since new rubber plugs could not be found. We acwuired new plugs, removed the transmission, and to our surprise, the plugs were too small. Looking at the situation, i quickly gathered that the wholes might be tapped with a pipe tap, and then a pipe plug installed to remedy our situation.
Using a 3/8-ths pipe tap (nearest recollection), coat the tap with axle grease in the flutes to catch as much of the shavings as possible, and on as straight an possible (some angle is required due to case interference) slowly turn the tap with a wrench a quater turn at a time allowing the metal to rest every couple of turns so as not to split the case. When a comfortable depth has been acquired (going too deep could split the case as well, only go about a 1/2 inch, as deep as the plug is tall), Put some thread tape on the threads of the 3/8-ths pipe plug and slowly turn it into the newly taped hole. The end result, if done properly should look something like this:
***This worked for us, if you attempt, you take the risk into your own hands. We are not liable for any issues that arise in you doing this. This is not a step by step how to, it is merely a suggestion and how we went about fixing the problem.***
Using a 3/8-ths pipe tap (nearest recollection), coat the tap with axle grease in the flutes to catch as much of the shavings as possible, and on as straight an possible (some angle is required due to case interference) slowly turn the tap with a wrench a quater turn at a time allowing the metal to rest every couple of turns so as not to split the case. When a comfortable depth has been acquired (going too deep could split the case as well, only go about a 1/2 inch, as deep as the plug is tall), Put some thread tape on the threads of the 3/8-ths pipe plug and slowly turn it into the newly taped hole. The end result, if done properly should look something like this:
***This worked for us, if you attempt, you take the risk into your own hands. We are not liable for any issues that arise in you doing this. This is not a step by step how to, it is merely a suggestion and how we went about fixing the problem.***
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