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Old 10-21-2012, 03:17 PM   #1
Indivisible
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Default 94 Gas Marathon rear end fluid change process/procedure help

Any tips or advice on what to use and the process for changing the fluid out on the rear end of a '94 gas Marathon? Looking to do it right now but all I could see was a "2 stroke Dana rear end" procedure in the stickys-Thanks guys
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Old 10-21-2012, 03:34 PM   #2
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

I just pulled the bolt out to drain it, and put 90W gear oil in mine. That was a couple years ago and haven't had any issues with it.

I used a sucker pump to put the fluid in. Looks like a grease gun but with a 3/4 hose for sucking out or pushing in fluid
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Old 10-21-2012, 03:52 PM   #3
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

Thanks brother, I was just going to use 80wt gear oil, but I don't know the actual mfg. specs do you? Recently, the cart has been spooling up for a second then a bit of a "clunk" then it starts pulling forward- I'm hoping its just a bit low and I'm not having a clutch issue- fingers crossed..
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Old 10-22-2012, 12:15 AM   #4
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

Well I just ended up filling it with some 80 Valvoline gear oil- pulled the cap, stuck my finger in, it was bone dry.. dropped a tube and tried to pump- nothing.. since I bought the cart and have been driving it (at least 20 miles I've put on it) the rear axle has been BONE DRY.
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Old 10-22-2012, 05:36 PM   #5
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

There is a drain plug on the driver side bottom between two of the case bolts. There is a oil level plug on the driver side rear just below the axle center line. Drain the case, replace plug, remove check plug, fill case with engine oil, 30wt, until it runs from the check plug, replace plug. These are not to be filled to the yellow fill plug, that will cause leaks. Gear oil is to heavy and will rob power. You would be hard pressed getting a tube past the differential gears far enough to pump oil out.
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Old 10-22-2012, 06:02 PM   #6
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

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Old 10-23-2012, 12:37 AM   #7
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

SWEET you guys RULE!! I missed the drain plug... now to drain 13 bucks worth of brand new gear oil..
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Old 10-28-2012, 10:54 AM   #8
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

if it's still clunking into gear, check your cables. They may be worn out or stretched. When my cables went bad, they didn't break but when i put it in forward, the handle went into the right position, but the rear end would be slightly out of forward until the engine was started then clunk.. it was in.

I never liked the two cable design so I installed the set up from a 2005 with a single cable for forward/reverse and it works alot better and doesn't freeze up in the snow
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Old 10-28-2012, 01:54 PM   #9
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Default Re: 94 Gas Marathon rear end fluid change process/procedure help

I also converted mine to the single cable. It shifts alot easier. The single cable is better with the v-twin conversion, the longer set of dual cables are too long making it more difficult to shift.
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