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Manual transmission genius needed

852 Views 35 Replies 8 Participants Last post by  Joey_Twowagons
OK now this is kind of strange but,may help me or others. I have a 1995 escort 1.9 5 speed,can't get the speedometer drive our to check or fill the transmission. This seems to be a common problem. Here's where it gets weird,back in the 80s/90s Audi decided their differentials didn't need to be drained or filled(sealed unit) then someone figured out that was a great theory but not a real world good Idea,so they put out a bulletin on where to drill and tap assembled differentials for drain and fill plugs. Does anyone have a case apart to see where we could drill and tap for fill plugs on the escorts? Okay,if not does anyone know how to determine which speedometer drive I need to have on hand for when mine gets destroyed on removal?
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Nearly all of the used parts I've received have had something wrong with them. The clerks too often don't check and just assume user error.

There are procedures for retailing return items as "open box" (with an almost negligible discount).

Management needs to do better about checking to see that return items are properly handled.
So I've run three parts stores including one of mine own,worked just as a counterman at 2 more. My bestvyear I sold 1 million 500 thousand dollars worth of parts. I've seen what people bring back. These people cost everyone money. Example 1 part store I worked at a guy bought a battery,the next day he bought a starter then he came back to warranty his new battery,then he bought an alternator. He returned the starter,no box and greasy we warrantied a battery,and what he needed in the first place was an alternator. Will you pay full price for the returned battery,the starter that's obviously been installed? There's tons more many costumers abuse the good will and customers always right attitude of parts stores. Techs that buy new belts then return their customers old belts under the lifetime warranty.I could go on and on Dennis asked someone a question about their water pump,customer response,they're all the same! No sir I need to know whatever he needed to know.The man answers takes the pump installs it,its the wrong depth because he didn't answer the question correctly. This is employee time, this is extra merchandise cost, think what you want but using the parts store as a test part library socks for everyone except the person doing it. Twice in the last month or 6 weeks on a different forum people giving advice just buy everything it could possibly be and return what you don't need. I told them that's a d!ck move.
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Regarding the fill port: I've done them just to preserve my sanity.
I borrowed my wife's ex's Escort for a trip, didn't really know what I was doing, thought I'd help out by changing the fluid in the 5-speed. Drained the fluid, then discovered that I couldn't remove that speed sensor. Ended up paying the ex for a tow to have the dealer remove it.
Four years later, I won the car, now it needs a clutch. got it done, take it out, clutch is good, but randomly I'm locked out of various gears. In reinstalling that speedo gear, I thought I was running into opposition from the sealing o-ring because the plug is such a snug fit. Wrong. The two gears weren't meshed properly, I forced it, and the gear ended up at the bottom of the case, where it was blocking the shift mechanism. Pulled the transaxle, opened the transaxle, retrieved the gear & clip (undamaged), reassembled the transaxle, reinstalled the transaxle, drank heavily.
Another few years, another Escort, another clutch, fill the transaxle, reinstall the speedo thing, car runs great, but no speedo action. I'm not sure exactly what it is (for this one I used some heat shrink tubing to ensure that the clip stays put). I no longer CARE. I don't need a friggin' speedo! I just need to NOT go back in there again. here are photos of my fill/check port, this allows me to drop a dipstick straight down past the inside of the "elbow" of the air inlet. I've seen several times that it'll leave a puddle of ATF at startup, and it's pooling on the top, so I guess I overfilled it, and it's leaving via the vent. This motor/trans was used in the SpecRacer Ford series, and there's some suggestion for purposely leaving the level low, so it doesn't drain out and make a mess
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when you pull if you change the axles. Sounds crazy.
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Did you tap and use a pipe nipple? I pulled the top off my vent,clamped a piece of hose on and use a fuel filter as a vent so dirt can't get in. I figure with no major leaks evident as spots where I park. Once a year drain,pull the filter/vent out of the hose and fill with 2.5 quarts at ought to be fine. Most people never even check theirs at all so I think an annual drain and fill will be plenty.
Did you tap and use a pipe nipple? I pulled the top off my vent,clamped a piece of hose on and use a fuel filter as a vent so dirt can't get in. I figure with no major leaks evident as spots where I park. Once a year drain,pull the filter/vent out of the hose and fill with 2.5 quarts at ought to be fine. Most people never even check theirs at all so I think an annual drain and fill will be plenty. If you tapped for a pipe nipple I'd like to know. I'd like to have a barbed fitting for my filter/vent.
View attachment 55739 Okay who has a 5 speed transmission side pan they can sacrifice for a worthy cause,or sell to someone else that can use it for a worthy cause. Here's what I have in mind on post 1 I asked if there was any place to drill a hole for transmission fill. Well I think someone can figure out (I will figure out just not immediately) where we can drill a hole in the sheet metal transmission to check fill level. A hole drilled X.x number of inches from some landmark on the pan.You fill or check from the weep hole just like most manual transmissions,differentials and even holley carburetors.You seal the weep hole with a sheet metal screw and a rubber washer. For filling you pull the factory vent off the Transmission you add a short piece of rubber hose and use a G.M. differential vent they clamp into a 3/8 hose. Anyway someone,maybe me needs to figure out where to drill the weep hole and/or if it's possible to drill a weep hole big enough to act as a fill port also and use an automatic transmission add on drain plug to seal the fill/check hole. View attachment 55739
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Had trouble with pics so had to start another post anyway I know the washer would have to be oil resistant this one's just so you have a visual.also pictured gm differential vent and transmission add on drain plug.

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View attachment 55739 Okay who has a 5 speed transmission side pan they can sacrifice for a worthy cause,or sell to someone else that can use it for a worthy cause. Here's what I have in mind on post 1 I asked if there was any place to drill a hole for transmission fill. Well I think someone can figure out (I will figure out just not immediately) where we can drill a hole in the sheet metal transmission to check fill level. A hole drilled X.x number of inches from some landmark on the pan.You fill or check from the weep hole just like most manual transmissions,differentials and even holley carburetors.You seal the weep hole with a sheet metal screw and a rubber washer. For filling you pull the factory vent off the Transmission you add a short piece of rubber hose and use a G.M. differential vent they clamp into a 3/8 hose. Anyway someone,maybe me needs to figure out where to drill the weep hole and/or if it's possible to drill a weep hole big enough to act as a fill port also and use an automatic transmission add on drain plug to seal the fill/check hole. View attachment 55739
FOJY-7222-A ,still some available........

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If someone doesn't answer in the mean time. I'll answer this for everyone next time I change transmission oil. I think it will be helpful for a guy just to know where to sink a self tapping sheet metal screw to check level and know they can top off using a GM differential vent.
I think a much cleaner installation would be with a socket head 1/8 NPT plug, or a BSPP plug.
An NPT tap is much easier to find or borrow than the BSPP tap.

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Brass NPT plugs available at local hydraulics stores etc.
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Looks like you can get the BSPP in stainless for about $2.50 including shipping from Aliexpress. Way better than when I was a kid!
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Not enough meat in that steel pan to tap
I forgot we were talking about the steel side cover. I was thinking of a drain in the aluminum part.
What about welding a female "bung" to the cover? Then screw in the pipe plug.
Yea I will probably weld a bung in mine,I was looking for an easier solution for other people that may not know how to weld,or have a welder. Everybody has access to a cordless drill. They put a self tapping screw with a rubber washer,zip it into the pan,once we figure out best location take the screw back out,shake the car nothing dribbles out,add fluid. For the fill port if they replace the existing vent with the G.M. vent on a hose,no drilling,no welding,add fluid through the hose.
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When you said "bung" I thought "bong" lol... What? How's he gonna weld a bong to a transmission... and more importantly why??
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Since we're veering off the track, how about that car club, the "Bungholers"?

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