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  #1  
Old 10-29-2015, 06:06 PM
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Rounded off Oil Pan Drain Plug

My drain plug has become rounded off and I'm unable to remove it. Any suggestions?

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  #3  
Old 10-29-2015, 06:22 PM
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Or tap on a socket of a smaller size.....done this a couple times...
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Old 10-29-2015, 06:23 PM
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I tried that it just rounded more. If i had a welder i would weld a nut on the end
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Old 10-29-2015, 06:28 PM
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Time to buy a suction tank.
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  #6  
Old 10-29-2015, 06:34 PM
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x2 on the vice grips.

and have a new drain plug and washer in hand.

i usually order a few spares when i get filters, etc.
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  #7  
Old 10-29-2015, 06:37 PM
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Irwin Bolt Outs or some similar designed damaged nut/bolt remover tools?

Bolt Extractors - Screw & Bolt Extractors - Tools - IRWIN TOOLS
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  #9  
Old 10-29-2015, 06:50 PM
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X2 on the Irwin bolt extractors. Used them all the time at the shop. Rounded nuts and bolts that looked like a damn beaver had chewed on them, and they cane right out.
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Old 10-29-2015, 07:49 PM
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I hope this doesn't sound insulting (not meant to be) but remember "righty tighty, lefty loosey". As a former plumber I can also recommend a good ol'-fashioned pipe wrench. They get tighter the harder you pull on them so the plug WILL come out with enough pull.

Vice Grips often work but there is a limited amount of "squeeze" you can apply with them.

Good Luck!

Dan
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  #11  
Old 10-29-2015, 11:24 PM
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I have the same situation on my '97 E 300 D, which came very rounded off. I also have a new drain plug, but, I have reefed on it as much as I am comfortable with. I am afraid I will end up with no threads in the pan. So about 7 years ago I resorted to sucking the oil out with a Topsider. Now I would not use the drain plug if it worked.
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  #12  
Old 10-30-2015, 09:55 AM
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Don't worry about stripping the threads. Just tap the hole to the next NPT (National Pipe Thread) oversize (probably 1/2 in most cases). You'll need a tapered pipe tap but they're commonly available. I use a brass plug so it won't seize in the hole. I've done a ton of 'em and it works great.

Dan
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  #13  
Old 10-30-2015, 10:55 AM
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Vice grips for sure... a while back I grabbed these on sale. You can clamp them on, then twist them down tighter with a screw driver through the clamping bolt... I have ez-outs and the like, but why use the right tool for the right job if you don't have to?

Also, nothing but box end wrenches on oil plugs. That wasn't obvious to me for way too many years.
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  #14  
Old 10-30-2015, 12:34 PM
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Quote:
Originally Posted by Ears View Post
My drain plug has become rounded off and I'm unable to remove it. Any suggestions?
As another poster said, use a topsider oil extractor. Saves a lot of mess and aggravation in dealing with the drain plug.
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  #15  
Old 10-30-2015, 03:29 PM
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+1 on the oil extractor. Those are awesome

If that's not an option then I'll +1 the pipe wrench option. Remember to use a new copper or aluminum gasket on the new drain plug and find and heed the torque spec

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