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> Stripped oil drain plug
smj
post Sep 3 2015, 01:21 PM
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"Dude, Steve from Berkeley."
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Bringing the 914-4 back from mostly sitting for the past three years (under 1,000 miles in all that time), I forgot the oil drain plug was boogered up by a DAPO or oil change place...

Based on what came out, there were only a few shreds of thread somehow attached to the bottom of the drain plug hole, and a horribly mangled soft crush washer. Most of the "bore" is pretty smooth, with some original thread left at the top. Pic below.

My question is how to fix this. I see references to Heli-Coils, but somewhere I got the impression they need some thread left...? Whereas a Time-Sert or similar requires boring and fitting a thread insert.

How difficult is it to do this right with something like a Time-sert for a guy that reassembled some CV joints correctly on the *second* try? With the car up on jack stands in the back, so at an angle. And then what the heck do I use for a drain plug?

Thanks!

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smj
post Sep 3 2015, 08:54 PM
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"Dude, Steve from Berkeley."
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Group: Members
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From: Berkeley, CA
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BTW thanks to everybody for your replies, I really appreciate this.


QUOTE(Series9)
Clean it thoroughly, take it to a welder, weld it closed, drill it out, tap it.

No question that's The Right Way, but as others have said I imagine I'd have to pull the motor and split the case. That isn't really going to be my first choice, absent other issues...


ADDED: A 3/8" NPT tap was $9.99 and a 3/8" plug was $1.99.

The stripped bore is ~13.75mm at the mouth. Using calipers to measure the outermost diameter of the plug is 16.85mm. The pointy end of the tap is ~13mm, hits about 16.5mm halfway up, and 17.05 at the wide end of the threads. So it looks like I've got to drive that tap most of the way in to get a proper fit for the plug, but I'll take it in stages and check fit along the way. I expect the going will get a lot harder when I hit the original threads ~9mm in.

That is, once I get something to handle the 1/2" square butt of the socket. Didn't think about that when I bought it - the tap & die set I have is for things like #8 machine screws... (IMG:style_emoticons/default/unsure.gif)
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