Oil drain plug won't budge

[vssman]

Hey boys I need help... I have one of those fancy Geno's drain plugs with the magnet in the end and it takes a 9/16 socket. Well, I went ot remove it today and it wouldn't budge. The ends easily rounded off and it looks like it's slowly falling apart. I know I didn't overtighen it at the last oil change but I can't get the darn thing off. I tried everything 6 pointed socket, wrench, etc... I even switched to a pipe wrench after the corners rounded completely - Nada. Went so far as a giant pipe wrench on the flange of the plug, not enough surface area to get a good grip and the pan was flexing so I stopped. Any ideas on how to remove a plug without buggering up the threads on the pan? :duh:

[Jim]

I got a set similar to this your more then welcome to try: http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200263424_200263424

[Stark9802]

i could try and see if i could loosen it by hand:falldownlaugh:

[Jim]

Another thought, maybe some heat will help? I wonder if its the Nylon washer ( I assume it uses one) that has swollen creating more resistance. Break down the nylon with a Mapp gas torch or something similar?:dunno:

[PRattenbury]

Darn, Jim, you're always running for the torch at the first sign of trouble. :smokin:

[Jim]

I learn from the best:poke:

[<T M T T>]

Dude no torch no extractors (E-z out type maybee).

Paul is it gold in color? It prolly made out of zinc pot metal type stuff. You mentioned that you said it rounded off easily.

[TORQUE THIS]

This would have never happened on a 24 valve... :stirthepot:

Paul, how did you make out?

[PRattenbury]

Jim, you done with the bumper yet?

[vssman]

It is beaking down pretty easily from the teeth of the pliers, vice grips, etc... Actually, the surface is gray and I think it's started to corrode. It won't budge even with a pipe on the end of my largest set of vice grips. I though about an easy out. I may try heat first and then the easy out route. If all else fails, I have a 4 1/2" grinder - carefully cut some flats on the flange and help cut down on some of the clamping force, but I'm sure this thought will end up with me replacing the oil pan. This looks like a project that needs to be started on a Friday...

[mal91152]

I would mig weld a nut to the plug and when you get it out buy a new plug and washer. Had to do that on another truck.

[Jim]

Hey Paul, (VSS) Did you talk to the owner? I saw he Posted on the TDR.

[95Cummins]

I would mig weld a nut to the plug and when you get it out buy a new plug and washer. Had to do that on another truck.

We've had to do that at work before, and it worked good, but never with a drain plug :dunno:

[vssman]

I'm going to weld a nut to the plug. It'll have to wait until next weekend at the earliest. Didn't call the vendor yet, but I'll do it later today to find out what steel the plug is made of. It looks like something attacked the surface of the hex (when it was still there). Really dull gray - like an old aluminum door. Could this be a sign of things to come as a result of the "new" salt DOT is spreading on the roads??

I swear this stuff only happens to me... You know - a couple of weeks to change the oil, all day to time a P-pump just to find out it's already advanced... :poke:

Paul

[Jim]

Got it down to under 2 hours now Paul, and even know how to see if its advanced before tearing into it:stirthepot: :falldownlaugh:

[DMcpherson]

sounds like its a pot metal plug anyway, and I dont think you want to try and weld that bad boy.

[vssman]

Talked to the vendor - it's a piece of low carbon steel machined to shape. Welding a nut or grinding 2 flats on the flange are probably the best way to remove it. Talking about bad luck... Did I ever tell you guys the day I put the 370s in the transfer case S.T.B.? Talk about a :nutkick:

[vssman]

It's out... I tried the 'weld a nut' trick. The first nut I welded on took most of the remaining nub of the hex off. It must have been corroded as I had one heck of a time to get a decent arc. It was just burning away and raining metal drops. I then tried the largest nut I could find in the tool box and rewelded it to the plug REALLY good. 1 1/16 socket and an imact took it off. I can't believe I would have overtightened it to the point that I would ahve to go through all of this because the threads were not damaged or galled at all. The old plug is back for now until I get another one like a took out. Next time I'll probably paint the outside of the plug with POR15.

[mal91152]

Glad to hear success, and the heat from the weld usually helps loosen stuff.
Back on the road is a nice feeling.

[DBogo]

my drainplug is always a paint in the a$$ to get out, i dont overtighten it neither