OK - after spending 2 hours unsuccessfully trying to remove the fill plug ( a tight spot and a snug bolt!), I am considering just pouring the prescribed amount of oil through the shifters - I don't see why you would need to remove the fill plug in this case if you pour in the amount the manual dictates?

My other question is - how do you remove the shifters - I've lifted the boot and see the rubber boot below around the shifters but have no idea what to do to reach the tranny from here - thanks.

Get you a ratchet and an extension with the socket on it. On mine, there is the main shifter boot, then a small little rubber boot that goes directly over where the shifter bolts into the transmission. Pull that up and you should see the bolts holding it in.

Here is the reason I pull the fill plug. I pull it because I have seen discrepencies from manual to manual on how much it takes. Just call it being cautious so that I get the right amount in there ... not too much, not too little. For me, I got a long handle wrench (not ratchet and socket) and put it on there.

Richard <img src="/forums/images/graemlins/patriot.gif" alt="" />

Richard, thanks - yes, a long handle wrench for the filler plug I had thought about, but don't own one with the proper angel, and length - a new tool to buy for sure.

The rubber boot that exposes the bolts, I see that but wasn't sure exactly how to pull on it - so I'll be gentle and try to pry it out.

Here's a new problem perhaps you and the others can help me with - turns out the filler plug on the transefer case was loose. This might explain why its somewhat wet on the outside. Upon unscrewing it, I found what appeared to be something like plumbers teflon tape on the threads - grey in color. When I went to replace the bolt, I see what the last guy may have tried to do - secure it with whatever the "stuff" was because while the bolt does screw in, it never tightens fully so I am guessing the case threads are stripped or ruined to some degree - the bolt threads look fine. For now I put it back with blue thread locker - any advice on what to do is appreciated!

Torque on all these bolts was unreal! Are they around 300+ ft-lbs? I see by the manula that for 24mm bolts not otherwise specified this is the case.

If you put 300 ft lbs on those bolts, you'd strip it out for sure. The case is only aluminum.

If it's stripped out, see if you can buy an oversized plug. They're made slightly bigger, like by a hair, so that it cuts new threads without having to drill the hole out. Also, I know some people on here have run rubber freeze plugs as a temporary repair at least. On those, just find one that's slightly undersized so that when you tighten the nut on it, it tightens up really well.

Richard <img src="/forums/images/graemlins/patriot.gif" alt="" />

I feel your pain. I had to go out and buy a 24" breaker bar and a 6 point 24mm socket to pull the fill and drain plugs on my Rodeo. Seriously consider finding a 6 point 24mm socket, because I had my Rodeo on jackstands ready to go but I only had a 12 point socket and I started to get a bad feeling about rounding off the bolt so I stopped to go get a 6 point. That is definitely one of those bolts that you do not want to damage.

Oh and someone on here mentioned that it was messy to drain the transmission. Just make sure to take the skid plate off before doing the transmission and there should be very little mess. Yes you can change the transmission oil without pulling the skid, but pulling the skid plate is easier than sweeping up oil-dry in my opinion.

Oh and by the way, I think the spec'd torque for those bolts is somewhere around 25 or 30 foot pounds.

Now remember, this is going by the size of the BODY of the bolt, NOT the HEAD of the bolt. While the head on this bolt is 24mm, the body of it is not.

Richard <img src="/forums/images/graemlins/patriot.gif" alt="" />