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Oil Drain Plug Saga - Done!
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Posted by PGAero [Email] (#1143) [Profile/Gallery] (more from PGAero) on Mon, 20 Aug 2007 16:00:41 Share Post by Email
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So, there was a post here a couple weeks ago about a seized oil drain plug. I chimed in with the same problem and was hoping to find the magic hint to take it out.

After rounding the head with a socket, then taking more material off with vise-grips, applying heat, using a dremel to make a nice "new" torque-application surface, and soaking with anti-seize products, I gave it a rest, and drove the car for a while. (I usually change my oil at 5000 mile intervals, a few miles wouldn't hurt, and the oil remained clean and I didn't loose any.) The Craftsmen extractors were suggested and had been successful for others, so I thought I'd give them a try.

So, on Saturday, I took it back out to the shop and my brother and I put it up on the rack. The # 5 extractor fit nicely on what was left of the head and after driving it on snugly with a copper hammer, proceeded to try to remove the plug. No luck... get an air impact gun. Wouldn't budge... get a larger air impact gun. The drain plug still wouldn't budge, but the drive shaft on the extractor sheared right off. Dang!

So, get the grinding wheel out, cut a slot through the center of the drain plug. Using the same impact gun, I proceeded to bend the snap-on flat screw driver blade, and foul-up the freshly cut drain plug.

Yeah, we ground the whole remaining nub off the flat of the drain plug, and ground as much of the skirt off, to relieve pressure between it and the copper crush ring. These new cuts left a pretty nice surface to try the vise-grips on. Well, I barely believed it myself, but a swift hit on the vise grips with a copper headed hammer broke it lose.

The oil looked fine, and the (shiny) new drain plug holds the new stuff in there just as designed. That was the most involved oil change I've ever done. The next step would have been a trip to the local 10-minute oil change place...

"Yeah, I'll be back in about 20 minutes to pick it up. I brought my own oil and filter. Oh yeah, by the way, there's a new drain plug with the filter... you know, if, for some reason, you find that you need to replace the one on there."

~Peter
'93 9000 Aero, 5spd, 87K

posted by 75.26.17... 
_______________________________________
Past:
'06 9-5 Combi, AT, Polar/Black
'04 9-5 Aero Wagon, AT, Nocturne/Granite
'03 9-5 Aero Wagon, 5spd, Polar/Black
'03 9-5 Aero Wagon, AT, Steel/Charcoal
'00 9-3 Viggen, 5D, Silver/Black
'93 9000 Aero, 5MT, Cirrus/Black (Owned this one twice... my favorite)
'86 900 SPG, Edwardian/Buffalo Grey
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