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Old 06-03-2013, 08:58 AM   #1
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Oil drain plug stuck and stripped

What I thought would be an easy job has turned in to a nightmare. I went to chnage the oil in my Onan QD 7500 Generator and the oil drain plug would not budge. I used penetrating oil and heat. After the bolt head stripping with a socket, and then stripping more using my Craftman bolt-out set and then finally vice grips, I now have a pretty well rounded bolt head that will not come out. I have a 2004 Monaco that I purchased last August. I am not sure if the oil plug on the generator has ever been removed.

Any ideas out there? I am at a loss.

Thanks,
Todd
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Old 06-03-2013, 09:07 AM   #2
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Drill a hole big enough to get an E-Z out in it. Your going to have to fix it anyway. Or, leave it alone, get a vacuum pump and change oil that way.
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Old 06-03-2013, 09:17 AM   #3
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Drill a hole big enough to get an E-Z out in it. Your going to have to fix it anyway. Or, leave it alone, get a vacuum pump and change oil that way.

Ditto on the transfer pump ... not much oil in an Onan. That's how you do a boat engine.

http://www.harborfreight.com/multi-u...ump-66418.html
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Old 06-03-2013, 09:27 AM   #4
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I ran into this a few times. I always went for a permanent fix. I would drill a small hole in the drain plug. Very carefully drill larger and larger holes until the hole was almost into the threads. I would try a easy out. If that failed, I would take a small chisel and go to the smallest edge of the drain plug and cut out the plug.
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Old 06-03-2013, 09:28 AM   #5
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Being that the bolt head is already rounded off, do you have enough room for a pipe wrench? They are 'made' for round objects. Other wise it looks like you are going to have a 'messy' job getting the plug out. If possible 'suck' the old oil out before you work at removing the old plug.
Any idea why the plug was installed so tight to begin with? There is no need for that.
Good luck and keep us posted.
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Old 06-03-2013, 09:46 AM   #6
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This is rather odd that the bolt is that tight but I have used an air hammer and a chisel bit to remove bolts like this. Make sure the bit is fairly sharp and dig into the bolt slightly and then remove. Make sure you are going the correct way (please take no offense lefty loosey righty tighty). Maybe even check into if the bolt is reverse thread for some odd reason.
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Old 06-03-2013, 09:51 AM   #7
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Another thing to try is to gorilla grip that bolt with vise grips. Have someone with a larger punch and hammer and hit the head of the bolt while you try to loosen up the bolt. The hammer shocks can also help break loose stubborn bolts.
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Old 06-03-2013, 09:54 AM   #8
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I ran into this problem once so I drilled out the old plug to a size I had a pipe tap for and tapped the old plug to that size. Then used a new pipe plug coated with anti seize to fill the hole. Use a new filter to remove any small cuttings that might not get flushed out.
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Old 06-03-2013, 11:44 AM   #9
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Or how about welding a new nut to the old drain someone correct me but you might need to disconnect some wires
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Old 06-03-2013, 02:50 PM   #10
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Welding a nut to the existing one (or bolt) is where I'd start. It also applies enough heat to possible free it up (much more than a blow torch). If that fails, drill progressively larger, expect to have to heli-coil or repair it after though if you drill..
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Old 06-03-2013, 03:29 PM   #11
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Exactly should he unhook the battery's?
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Old 06-03-2013, 04:22 PM   #12
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Welding a nut to the existing one (or bolt) is where I'd start. It also applies enough heat to possible free it up (much more than a blow torch). If that fails, drill progressively larger, expect to have to heli-coil or repair it after though if you drill..

by heating up the bolt, you expand the bolt into the welded nut in the pan. If this is to be done, everything will need to cool off before trying to remove a heat enlarged bolt out of a nut sitting in engine oil.
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Old 06-03-2013, 07:59 PM   #13
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I have welded on my MH a few times. Each time I disconnected AC power, and both chassis and coach batteries (at the battery not the switch) before welding with no problems.
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Old 06-03-2013, 11:25 PM   #14
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what whem to fish said tack weld a nut on the base, if threads are mussed from the sounds of it install a HELICOL easy stuff
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