What is this Man Trans Plug?

[BonesDT]

my manual transmission was leaking trans fluid. i lost about half my fluid. it seemed as if the fluid was leaking through this pink plastic plug, which is neither the fill or drain plug. i removed the plug and the back is melted and destoyed.

what is this plug? is it a release valve of some sort?

why did this happen? the transmission was brand new less than 2500 miles ago.

how can i replace this with something of better quality?

 

[BonesDT]

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[BonesDT]

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[BonesDT]

i just bought a bottle of champagne! ill use the cork temporarly. if it doesnt work, it wont be that bad a loss!

 

[MEXEXP]

I think I read something about those plugs, and you can replace them with some Dana Metal ones, but I can't remember where i read it and what's the number, a friend of mine busted up his manual transmission because of those plugs his transmission was bone dry and the plugs melted and wen't inside the transmission.

 

[Rick]

Mazda 5 Speed Manual Transmission
Many Explorer/Navajo owners have went with synthetic transmission fluid hoping to extend the life of the transmission. I use Redline's Mercon/Dexron III synthetic fluid. Synthetic fluid handles high temperatures and pressures better then conventional fluids.

Another preventive maintenance tip is to replace the rubber plugs in the shift rail bores with steel freeze plugs. The rubber plugs have a tendency to dry up and leak, and/or fall out. The plugs are located in the transmission top cover and face towards the rear of the truck. The part numbers for the metal plugs are: Dana #219-3052 or Dorman #555-108, you will need 3 plugs to do the job.

The hydraulic clutch, slave cylinder/throwout bearing is another item you should pay close attention to. After time, the slave cylinder fails to release the clutch completely. If you are having trouble shifting into 1st and reverse while stationary or if your truck creeps forward with the clutch pedal depressed the slave cylinder/throwout bearing is probably at fault. Unfortunately there is no easy fix here as the transmission must be removed to replace the combination slave cylinder and throwout bearing.

 

[BonesDT]

thanks guys. its good to know this may be a common problem and there are quality replacements out there. just to clear things up a little bit though, this is not one of the three rubber plugs in the shift rails. this was a plug that is about a couple inches to the right of the fill plug and is on the extension housing. i wish i had a better look inside the extension housing before i installed my transmission, but even though the plug is on the outside of the ext housing, it doesnt seem like thats where the fluid is coming from, it seems like the fluid comes from the main transmission housing.

 

[BonesDT]

the cork seems to be leaking slightly now.

i dont get this. why is there so much pressure? am i overheating the transmission?

i cant find the replacement metal plugs, where can i get them?

if i replace it with a metal plug, then there will be no way for heat build-up to escape. would this be a problem? if transfer cases, auto trans, and diffs need a breather hose, how come man trans dont?

 

[Bwana Bob]

PLUG

That plastic plug loks like a "caplug", a temporary cap used by the factory to keep dust and dirt out until final instllation when a permanent plug or fitting is installed.
Caplugs are typically used on connectors and pipe fittings during shipping and prior to assembly. Maybe that plug was supposed to kave been removed and something else installed in its place.

 

[BonesDT]

yep, thank you, i went to ford today and now it all makes sense. the plug was meant to be removed and looks like there should be some sort of sensor to replace it, such as an OSS (output speed sensor).

 

[BonesDT]

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[BonesDT]

can anyone with a manual transmission take a picture for me of this area?

why would i need an OSS for a manual transmission?

is it only need if you have an electronic transfer case?