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Old 04-23-2013, 09:45 AM   #1
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Rounded off oil drain plug

Rounded off and stuck oil drain plug on Onan diesel generator. I have tried just about everything including large visgrips. Any thoughts?
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Old 04-23-2013, 09:55 AM   #2
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A couple.

See if yo can get a pipe wrenceh around the head. P{ut a cheater bar on the wrench.

Next is is messy. You need to drill the center of the plug as deep as you can and use an easy out to remove it. Be sure to have a drain pan in place.

Takes skill and talent. Usining a file or grinder flatten the plug head and repeat step 1. Good luck.
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Old 04-23-2013, 09:58 AM   #3
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I have also used a rotary cutter to make a notch in the side. You then take a chisel and a 2 lb hammer and beat on it until it starts to turn.
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Old 04-23-2013, 10:30 AM   #4
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Go to SEARS, or other place selling tools and buy a socket type attachment for a ratchet then removes rounded off heads.

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Old 04-23-2013, 10:45 AM   #5
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On our 1999 7.5Kw Onan diesel Kubota it came with a steel square drive head that easily rounded off and is up in a pocket.
I was successful by using an adjustable wrench pointing up tightened on 2 sides of the head then used a screwdriver thru the wrench gap for torque.
If you can get it out they sell a replacement hex head brass 1/4 NPT plug that works so much better with a std. 6pt socket. The key is don't over tighten but you already know that.
It has been such a problem that some have cracked the casting in the oil pan (Big $$ fix) from over tightening and that may be why the brass replacement.

Onan part # 502-0153

Was $3.43 + tax last year at Onan Cummins shop
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Old 04-23-2013, 10:55 AM   #6
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I'm assuming the plug is up in a recessed area where you can't get a lot of leverage on it?

If you have an old set of 12pt sockets laying around, you might try finding one (metric or inch) that would provide a snug fit with a LITTLE convincing from a hammer? This is not something I would hit with a big hammer, for fear of cracking the casting as mentioned earlier.
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Old 04-23-2013, 11:26 AM   #7
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I have also used a rotary cutter to make a notch in the side. You then take a chisel and a 2 lb hammer and beat on it until it starts to turn.
While in the Air Force, the fuel tank access plates had many, many flat head countersunk screws. Many times the Phillips screw head would strip. The solution was a chisel, and a brass hammer. Hopefully you have plenty of room to work. Cut the notch in one half the head, then angle the chisel and hammer it loose.
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Old 04-23-2013, 02:11 PM   #8
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stuck plug rounded head

Heat the plug with propane torch use your vise grips then while holding tension hit the plug with a hammer. Heat and vibration work wonders
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Old 04-24-2013, 11:34 AM   #9
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Here is the place for import tools...

Get a elcheapo socket that is almost big enough.

Tap it onto the plug.

Now tricky part...

If can get impact wrench to fit use it on LOW power, if not, add breaker bar, apply firm and constant pressure, then tap the plug with hammer, combination of firm pressure and viberation from hammer and it will let go.

Both must be at same time
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Old 05-03-2013, 02:12 AM   #10
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My way is to drill and use a ez-out to remove the plug but first go to a auto parts place and find a plug with a built in valve to replace it

That way you never have to remove the %*$@#^& plug again.
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Old 05-03-2013, 02:32 AM   #11
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You could just leave the plug in and use a pump to remove the oil through the fill hole.

They make small hand operated pumps designed to do just that.
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Old 05-03-2013, 03:02 AM   #12
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if the plug is steel, and you have room get either a grade 5 or 8 and weld the outside to the plug. if it is recessed, hold the nut against the plug, and weld the inside of nut to the plug, making sure the outside of nut gives you enough room to get either a socket or wrench on the nut. between the heat from welding and the new surface to grip it will come out. be sure it is a steel oil pan.
have done this many times on all sizes of both stuck bolts or nuts.
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Old 05-03-2013, 03:17 AM   #13
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Originally Posted by Ed-Sommers View Post
Go to SEARS, or other place selling tools and buy a socket type attachment for a ratchet then removes rounded off heads.

Ed
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Old 05-03-2013, 04:32 AM   #14
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You could just leave the plug in and use a pump to remove the oil through the fill hole.

They make small hand operated pumps designed to do just that.

X2!
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