Leaking oil drain plug

[OldCrank]

Had truck at dealer for brake work (again, see post in 2nd gen forum titled "2nd gen brake upgrade?"). Decided to have them go ahead and change the oil/filters since they had it and I had a laundry list of other projects to complete. Nice new oil leak came with it at no extra charge. Response? "Bad oil pan, that'll be 1200 mazoolas if you please. Wasn't our fault. "

I pulled the drain plug to inspect the problem and found that the pan is indeed distorted. The pan has a threaded section inside the pan that is raised above the pan floor with four openings to allow complete drainage (sort of an upside down castle nut arrangement, which I've seen on other vehicles). Anyway, sure enough, there is just enough distortion at the points where the openings are located that oil gets out past the reach of the plug and seal. Obviously over-torqued and then some.

Yeah, I know, I should tapdance on the service managers desk and all that noise, but I want to fix it first, and put the hammer down after. I don't want them near it again, ever.

Gotta help me here guys. Does anyone make a drain plug with a larger diameter sealing area? Is this a common problem (there are no bulletins on it that I could find)? Another dealer said they never run across the issue. Other repair options? I replaced the seal, which made no difference, and have added a nylon washer that is a larger O. D. I'll know tomorrow whether that helped, but I need a fix that I can count on. Thanks in advance.

P. S. TDR is easily my favorite forum along with IATn (a technicians network).

BK

 

[VicR]

Hey - did we go to the same 5 star dealer? Mine did the exact same thing. On the advice of a fellow TDR member, I put 2 gaskets on the plug and its held fine for a couple thousand miles now. My back up plan was to buy one of the two part plugs from Geno's and RTV it into the pan an then never have to remove the outer part.



I am surprised they didn't break the collar off of the plug. They fractured mine, but of course didn't say anything about it.



Good luck!

 

[EMDDIESEL]

I have the heavy duty plug from Genos and tighten it to 40ft lbs. It has a thicker collar which will prevent the plug collar from cracking.

 

[OldCrank]

Originally posted by Vic R

Hey - did we go to the same 5 star dealer? Mine did the exact same thing. On the advice of a fellow TDR member, I put 2 gaskets on the plug and its held fine for a couple thousand miles now. My back up plan was to buy one of the two part plugs from Geno's and RTV it into the pan an then never have to remove the outer part.



I am surprised they didn't break the collar off of the plug. They fractured mine, but of course didn't say anything about it.



Good luck!

BK- Actually, they (my Very Local 5-Star dealer, hmmm, I'm at the base of the Sierras on Folsom Lake and you're in Reno... ) replaced the drain plug because they said it broke while they were taking it out. The Geno's plugs might do the trick, especially if I use the Finger Touch with some Ultra-Black on the gasket(s). I don't want to have to play this game at every oil change.

Thanks for the info, I'll order one up.

 

[Dreher]

BKeller,



I don't know if it could be called common, but this has happened to more than a couple of members. And I'll bet my truck that your dealer broke the plug tightening it, not taking it out.



On some trucks, when the plug is overtorqued, it will distort the sealing surface as yours did. I have had this condition for about three years and my plug does not leak a drop. As Vic said, the trick is to install another gasket between the factory washer and the oil pan. I am currently using a sheet of cork gasket material. I use the oil plug flange as a template and cut out a gasket. I then punch a hole in the center with a sharpened 3/4" copper pipe. I install the gasket, factory washer and the plug, and tighten to 25 ft/lbs. I change this gasket each time I change the oil and have no seepage at all.



Bob

 

[ASchwartz]

I agree, it is very common to over torque the drain plug. I was rotating my tires and changing the oil at the same time when I over torqued my drain plug. Luckily I had another vehicle to track one down.

 

[JMoglia]

Hey guys do yourselfs a favor and just go to Geno's and get the finger touch drain plug,never ever have to unscrew it again. good luck

 

[EMDDIESEL]

And never get all your oil out again either

 

[JohnE]

Kinda late for the lesson, but maybe some others will learn the drill.



If you go to ANYONE outside of your personal warranty station (your fingers) for any work make sure to point out to the service manager than your pan does not leak and is not cross threaded, oil filter seats well, etc. Remind them they will be responsible for any and all damage caused by the staff. Make sure to note this when signing the release papers. They expect you to sign the standard papers which included a complete acceptance/release for liability.



It may be as simple as a reversed drain plug seal. Mine seals best with rubber UP.



John



97 CTD