Engine/Transmission (1998.5 - 2002) Frozen brass oil drain plug

[Jdonoghue]

I've broken 2 3/8" drive 9/16" sockets (6-point) trying to get this oil drain plug to come out. It's a brass replacement plug from Geno's garage. I have never had a problem with it in the past, always used the torque wrench when tightening it. But it won't come out! Any suggestions? I have the standard Cummins washer under it. I'm off to get a 1/2" drive 6-point socket to try next, but I'm very afraid of shearing the head off of the plug.

 

[Timbeaux38]

That is odd. Could it have been cross threaded last time?

 

[Jdonoghue]

That is odd. Could it have been cross threaded last time?

I don't think so. I thread it in by hand until it seats then tighten with the torque wrench.

 

[SnoKing]

Hit it with a hammer, then loosen it - turning CCW. SNOKING

 

[FourBarR]

Take care with too much force the oil pan is very thin. I have seen the pan cracked trying to get the cummins plug out. you might try using a heat gun to warm it up.

 

[Signal73]

there is a post just like this in the 12 valve section with the same plug. becoming a common problem

 

[Signal73]

https://www.turbodieselregister.com/forums/showthread.php?t=180154

 

[rotohead]

I've had great success removing similar plugs, pulleys, pitman arm removal by moderate heating than take a very wet rag and put it on the demon and the sudden contraction will cause the hole to expand and shaft to shrink... just be careful when doing this with pulleys, pitman arms, etc as they can come off with some force. Old dairy farm trick...
Chuck

 

[Jdonoghue]

Got it out

Heated it a bit with a heat gun. Didn't do the trick. Heated it again with the torch, came right out. Thanks everyone for the suggestions!