Trail Toys Power Fill - Pressurized diff and tcase filler

SMKYTXN

SMKYTXN

Vendor
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We've all sat under our rigs with either a squirt bottle or a cheap vatozone hand pump filling the tcase or diffs. You'll all agree it's not fun. Here's my solution to the problem.

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My new Motive power bleeder gave me the idea. Motive actually offers a version of their system for gear oil, but at a cost $90 and a long lead time I decided I could build something just as effective.

Here's what you'll need to build your own Trail Toys Power Fill.

  • Some sort of pump up sprayer. I chose the smallest volume sprayer I could find, which turned out to be one gallon. You can pick one up at your local hardware store, or buy straight from Amazon for a mere $13.00. (This is the pump I bought from Amazon)
  • 1/4" Ball valve. You have to have a valve inline to be able to store the pressure you're putting into the tank. (Ball valve on Amazon-$5.00)
  • 1/4" Barbed fittings. Be sure to buy the correct fittings. If you have a female/female valve like I used you'll need male fittings. (Barbed fittings on amazon)
  • 1/4" ID clear tubing. To complete the kit you'll need a length of 1/4" ID clear tubing on the end of the ball valve. I chose to make mine about two feet long. That allows the ball valve to sit on the ground and not pull the tube out of the diff. The final length will vary based on your needs.
  • Thread sealer - Teflon tape or liquid sealant, your choice.

Here's what you'll do once you have all your parts in hand.

  • Assemble your ball valve. Apply thread sealant to the the male threads on both of the barbed fittings. Screw them into the ball valve till snug.
  • Assemble your new pump up sprayer per the included instructions.
  • Remove the intake screen on the dip tube as it could restrict the flow of the thicker gear oil. The filter was a slotted tube on my model pump up sprayer.
  • Attach the sprayer tube to the fitting on the tank.
  • You will be cutting the end of the sprayer tube just before the fitting that attaches to the sprayer wand. You will not need the wand, so it can be tossed.
  • You're now ready to attach your ball valve. Press one end of the valves barbed fitting into the hose leading from the tank. Then attach your clear tubing to the other end of the valve. I chose to put a hose clamp on each barbed fitting to prevent the tubes from blowing off under pressure.
  • That's it! You've successfully built your very own Trail Toys Power Fill!

One thing to note; If you fill the tank nearly full you will not have a large volume of compressed air in the tank. That will result in the pressure bleeding off before you've filled your diff. I suggest to fill the tank about half full only.

Here are a few pictures of the Trail Toys Power Fill in action.

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If you have any questions please let me know.

Nathan
 
Anathollo

Anathollo

Armorall is my choice of lube
Staff member
Thanks for the write-up! Ordered everything for this weekend. I need to swap out both diffs and transfer case fluid for the upcoming trip.
 
tgormtx

tgormtx

Vendor
Vendor
Time to package that up so we can sell it lol
 
Silverback

Silverback

Lima Gulf Bravo Foxtrot Juliet Bravo
I was going to peal the label off and duct tape it to the container.
 
tx_shooter

tx_shooter

It is not a war crime the first time.
Staff member
Pretty sure you could have the first 3-5 orders here already. Set them up to be filled with an air compressor for a certain PSI setting and that would be sweet.
 
SMKYTXN

SMKYTXN

Vendor
Vendor
tx_shooter said:
Pretty sure you could have the first 3-5 orders here already. Set them up to be filled with an air compressor for a certain PSI setting and that would be sweet.
Click to expand...

Would a pneumatic only tank be an option? Skip the pump up part. That would make for a more robust setup that could go to the trails and survive.
 
tx_shooter

tx_shooter

It is not a war crime the first time.
Staff member
That would be fine by me. It would be safe to say 90% of the off roading guys have access to an air compressor of some size. Just make it easy to add oil and see the oil level. Then an easy lever/ valve to control oil flow out. Where do we sign up to get on the R&D team? lol
 
SMKYTXN

SMKYTXN

Vendor
Vendor
tx_shooter said:
That would be fine by me. It would be safe to say 90% of the off roading guys have access to an air compressor of some size. Just make it easy to add oil and see the oil level. Then an easy lever/ valve to control oil flow out. Where do we sign up to get on the R&D team? lol
Click to expand...

Keep an eye out for vessels that will work for the purpose. I'm actually thinking a spun aluminum tank would be nice. This may be something I have to have custom made though.

As far as the testing team? I'll definitely need some testers, don't worry about that.
 
tx_shooter

tx_shooter

It is not a war crime the first time.
Staff member
Aluminum would be swanky but costly too. If you keep the psi down most any of the thicker plastic containers would work
 
Oswego

Oswego

n00b
I like the idea, but not enough to stop using the $0.99 hand pump I have been using for years that screws right onto the diff bottles. KISS. As I get older and cheaper I find some items are just better off left simple. All I imagine is me over pressurizing something and spraying diff fluid all over.

Ive used the same system to bleed/change brake fluids solo and in my prototype phase I didn't have the cap on the resi tight and brake fluid ended up spraying all over. Could also just be I'm a dumb ass so I don;t like compressed stuff?
 
tx_shooter

tx_shooter

It is not a war crime the first time.
Staff member
I have never had a hand pump last more than 2 diffs and they always end up getting thrown across the driveway.
 
Silverback

Silverback

Lima Gulf Bravo Foxtrot Juliet Bravo
Add a cap for the tip of the hose as well to prevent drips.
 
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