Lower unit fill procedure

jspriddy

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Aug 30, 2011
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I hope this is in the right forum. If not, I trust the moderator will move it to a more appropriate one.

I having trouble comprehending the necessity of filling the lower unit with gear oil by the procedure that seems to be universally accepted, that is filling from the lower hole until it runs out the top, then trying to start this tiny plug, which is at an odd angle, and where you can't really see, before any, or much oil runs out.

I've heard all kinds of reasons, air bubbles, the necessity to flush out contaminants, etc., but can't really see the validity of the arguments.

If you drain from the lower hole, and flush with fresh oil after draining, I don't see how flushing from the bottom up would be any better. In fact, the most likely contaminant would be water, which is heavier than oil and would be at the bottom of the gear case. You would be pushing it back up through the gears. Any metal contaminants would be drained or flushed out the bottom. Filling from the bottom would push these back up in the gears.

As for air bubbles, 80-90 weight oil is not all that thick. Put some in a clear container and blow in it with a straw. The bubbles come to the top, right? We've filled automotive gear cases for years from the top, sometime with much heavier oil, and it's not a problem with them. The only difference is that they are vented, or at least some are. I'm not certain if all auto differentials and transmissions are vented, anyway.

I just spent over an hour Sunday changing the oil in my outboard, what should have been a 20 minute job, so I had plenty of time to ponder this. Admittedly, this was my first time doing this, and with practice, I might get better at it.

If there's a question in this, I guess it would be why can't I go back now that the oil has had time to settle out any bubbles and top it off, if it needs it? With oil running out the top and bottom (I put the top plug in before disconnecting the pump), I'm not certain it's full.

Thanks, John
 

foodfisher

Captain
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Feb 18, 2009
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3,756
Re: Lower unit fill procedure

Filling from bottom just eliminates the wait for the air bubbles to rise and top off.
 

robert graham

Admiral
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Apr 16, 2009
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Re: Lower unit fill procedure

The accepted procedure with with the pump works great, very simple, not very messy. No reason to reinvent this wheel. Good Luck!:)
 

jspansel

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Oct 26, 2010
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126
Re: Lower unit fill procedure

If you do not have a separate "vent" plug, have you tried filling it up from the top with the drain still in? It is sealed so you really cant. There is no where in there for the air to escape from. So if you only have the 2 plugs, you need to do it from the bottom. Once it runs out the top, put the TOP plug in first. I used to try and put the bottom in first and it would all run out before I could get it started. Putting the top plug in first (while still holding the pump on the bottom) helps keep it all from running out.
 

jspriddy

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Re: Lower unit fill procedure

Filling from bottom just eliminates the wait for the air bubbles to rise and top off.

That's what I thought. So I can pull the top plug, and if it doesn't run out, top it off? If it does run out, it's ok?

John
 

jspriddy

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Re: Lower unit fill procedure

If you do not have a separate "vent" plug, have you tried filling it up from the top with the drain still in? It is sealed so you really cant. There is no where in there for the air to escape from. So if you only have the 2 plugs, you need to do it from the bottom. Once it runs out the top, put the TOP plug in first. I used to try and put the bottom in first and it would all run out before I could get it started. Putting the top plug in first (while still holding the pump on the bottom) helps keep it all from running out.

I put the top in first. The problem was getting the pump unhooked and getting that tiny plug started with oily fingers. They could have used an Allen screw so you would have something to start it with. I guess I could custom grind a screwdriver.

Thanks, John
 

jspriddy

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Re: Lower unit fill procedure

The accepted procedure with with the pump works great, very simple, not very messy. No reason to reinvent this wheel. Good Luck!:)

"Not very messy"??? Your fingers obviously have more dexterity than mine. Next time I'll call you and you can be standing by to plug it. It's not far from Greenville to Lamar County Alabama.:)
 

Fed

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Re: Lower unit fill procedure

Don't try & disconnect the pump & fit the plug in one go, use your left thumb as an intermediate step.
 

robert graham

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Apr 16, 2009
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Re: Lower unit fill procedure

A little clean lower unit oil is great for your skin...rub it in!...never get chapped up!....seriously, if the upper plug is in, you can easily remove the pump and replace the plug without losing more than a few drops of oil...so what's the big problem?:confused:
 

Sprky

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Re: Lower unit fill procedure

You don't want the lower completely full, gear oil expands when it gets hot. Not so much a problem on low hp motors, but on some of the mercury performance stuff, if you do not leave room for expansion it will push drive shaft seals up.

I have drained lowers with less than half of the required gear oil in them. Fill them up and they are still out there.
 

JB

Honorary Moderator Emeritus
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45,907
Re: Lower unit fill procedure

Maybe you just need to get someone who doesn't mind a bit of grease on his fingers to do it for you, js. The procedure was designed by people who know a lot more about it than you and I.
 

jspriddy

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Re: Lower unit fill procedure

A little clean lower unit oil is great for your skin...rub it in!...never get chapped up!....seriously, if the upper plug is in, you can easily remove the pump and replace the plug without losing more than a few drops of oil...so what's the big problem?:confused:

I felt like I lost more than a few drops. No big problem, just wondered why I couldn't remove the top plug and bring it on up to the bottom of the top hole. Just to ease my mind.

By the way, I do think my hands look nicer. Maybe you're on to something.

John
 

jspriddy

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Re: Lower unit fill procedure

Don't try & disconnect the pump & fit the plug in one go, use your left thumb as an intermediate step.

OK. My pump had a fitting with rubber O-ring that screwed in. Turning it and the pump and bottle left me one hand short. But I see what you're saying, and I tried that. My biggest problem was getting the tiny plug started in a place where I couldn't really see even lying down. I don't know how old you are, but if you're old enough, one word will tell part of my problem-bifocals.

John
 

jspriddy

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Re: Lower unit fill procedure

You don't want the lower completely full, gear oil expands when it gets hot. Not so much a problem on low hp motors, but on some of the mercury performance stuff, if you do not leave room for expansion it will push drive shaft seals up.

I have drained lowers with less than half of the required gear oil in them. Fill them up and they are still out there.

Now here is an useful answer. I was under the impression they had to be almost completely full, with little or no air whatsoever.

I think mine had less than half the required amount, though with what I lost, I'm not sure how much I got in it. One good fortune however. It was clean and crystal clear as new honey. No milkiness, sludge, nor metal.

Thanks, Sprky.

John
 

guy74

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Jul 12, 2007
Messages
794
Re: Lower unit fill procedure

Not sure what brand of outboard you are working on, but I have allen head plugs in my Johny-rudes. I found them at my local dealer, and thought it would be nice to have in all 3 of the LUs on my motors. It is much easier to handle the plug when it is on the end of a long T-handle wrench. I also tilt my motors up after filling and installing the top plug ( they all have T&T switches on the motor), makes it much easier remove the pump hose and re-install the drain plug.
 
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jspriddy

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Re: Lower unit fill procedure

Maybe you just need to get someone who doesn't mind a bit of grease on his fingers to do it for you, js. The procedure was designed by people who know a lot more about it than you and I.

"...doesn't mind a bit of grease..." "doesn't mind a bit of grease"??? I've spent the last 28 years running a one man (namely, me) tire, muffler and service center. Did I say by myself? I've had more grease on me than you've ever run through all the boats and autos trucks you've ever owned. Did I mention I didn't have any help? Until the invention of disposable gloves, my hands only came clean late Sunday night. By the way, I didn't have any employees, so if it got done, I did it. Did I mention that?

Sorry, JB. You're way off here. No seriously, JB, my problem was getting that d*&^ little plug started. And don't take me too seriously, no harm intended.

Cheers, and if you were here, I'd offer to share my wine with you.

I know the engineers know more about it than I, but I've also dealt with the problems engineers create. They're not infallible.

js
 

jspriddy

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Messages
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Re: Lower unit fill procedure

Not sure what brand of outboard you are working on, but I have allen head plugs in my Johny-rudes. I found them at my local dealer, and thought it would be nice to have in all 3 of the LUs on my motors. It is much easier to handle the plug when it is on the end of a long T-handle wrench. I also tilt my motors up after filling and installing the top plug ( they all have T&T switches on the motor), makes it much easier remove the pump hose and re-install the drain plug.

That's a good idea. I have a Yamaha 25, 1994 vintage, and I'd have to raise it manually, but that's no problem. I'll check with the Yamaha dealer next time I'm there about the allen head plugs.

I'm satisfied now that I know they don't have to be "slap full". As many auto gear cases as I serviced, common sense should have told me that. I'm going to take the top plug out, fish in it with a bent wire and see how much I have.

Thanks,

John
 

robert graham

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Apr 16, 2009
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6,908
Re: Lower unit fill procedure

One other important item, in your haste to replace that drain plug, be sure not to cross-thread it, as that can cause the loss of the plug, the oil, your lower unit gears and bearings. Always start screws and plugs carefully by hand so as not to cross-thread them. That long T-Handle Allen wrench could create a lot of torque, so don't strip out those threads! Good Luck! Hopefully after you do this a couple of times it won't be such a greasy ordeal!...:)
 

jspriddy

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Re: Lower unit fill procedure

One other important item, in your haste to replace that drain plug, be sure not to cross-thread it,...Hopefully after you do this a couple of times it won't be such a greasy ordeal!...:)

Thanks, Robert. That's a good point. I think Guy74's suggestion of raising the lower unit after replacing the top plug will help me. My main concern was that I wasn't sure how much I got in it after losing so much from the top and bottom. I still plan to pull the upper plug and just see how much is there, now that it has settled. Can't hurt.

John
 

Fed

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Apr 1, 2010
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2,457
Re: Lower unit fill procedure

You don't need to worry about how much you lose from the top, the top is the fill level.
 
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