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Old 10-29-2015, 11:06 PM   #15
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Stud extractor from local auto parts store worked great. Quick and simple. Tap it on with a hammer. Turn the plug out with a wrench. It was a LOT easier AND less risky than drilling, etc.
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Old 10-30-2015, 04:22 AM   #16
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Stud extractor from local auto parts store worked great. Quick and simple. Tap it on with a hammer. Turn the plug out with a wrench. It was a LOT easier AND less risky than drilling, etc.

Another vote for the extractor. If it doesn't work, you can still take the risk of drilling.



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Old 10-30-2015, 08:27 AM   #17
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Have also considered the valve option but was concerned about proximity to the road surface and the possibility of debris [a road gator-strike]. Once removed and a new plug is installed properly, doubt if the issue recurs......
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Old 10-31-2015, 02:00 PM   #18
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OK, the final chapter has been written. Success at last, thanks in part to all the advice and encouragement given here. I bought the bolt extractor set so I would have a smaller size after if I chewed off more of the plug head. It did chew off more but wouldn't budge. Still had some of the bolt stub showing so used a Dremel to cut a slot. Used a hand driven impact driver to try to break it loose several times, each time pealing off some of the bolt. No success. At this point, I was approaching drilling. So I used the Dremel to take the slot all the way to the oil pan but not cutting it. (okcnewbie . First couple of tries with the impact driver failed but didn't peal off the side. I was encouraged so used the flat blade bit from the driver, driving it fully in to the plug slot, used a break over and out it came. Wow. Tough little 1/4" pipe plug. Yes, dennis45, 1/4"NPT.

Thanks again for all your suggestions. It gave me great comfort to know I had another option or two after each failure. Jim
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Old 11-03-2015, 10:50 AM   #19
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Might consider drilling it out in the center of the bolt and use an easyout. That must really be stuck. Sorry for your situation.


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Old 11-03-2015, 08:46 PM   #20
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Cases like these an impact driver works wonders but best is pneumatic or new battery impacts.

They hammer most things out fairly well with minimal damage.
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Old 12-05-2015, 12:23 PM   #21
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Great information from a lot of knowledgeable people.
My problem hasn't deteriorated to that level quite yet but I'm afraid I'm headed there if I'm not really careful. I have 150 hours on a 10 month old Onan QD 10000. It calls for a 22mm hex socket for the drain plug. So far, even with a 24" breaker bar and then using a hammer on the bar too, I cannot budge it. Slipped off a couple of times so I'm sure I'm rounding it slightly at this point so I stopped trying. Do you folks think that heating the pan with a torch would loosen things up? I hate to give it to a "pro" for fear they would finish rounding the plug off. What say you? -Ron
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Old 12-05-2015, 01:10 PM   #22
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Whats with Onan and overtightening bolts .
Had to patch up the coolant overflow tank every single place they installed a mounting screw into it !!!!
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Old 12-05-2015, 09:53 PM   #23
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Use an impact wrench as they are designed for this.

If bolt is getting rounded look for a socket that almost fits that you can tap on.

This is a good use for the cheapest line of sockets at harbor freight as they are soft and can be tapped on to some odd shapes.

Hard pressure on gun to keep it tight against the pan to keep it from flying off.

Then LIGHT PRESSURE on the trigger and be sure it is in the right direction
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Old 12-06-2015, 05:33 AM   #24
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Keep that breaker bar off it, it will likely snap it off or certainly round it off. Battery impact with that constant hitting will work wonders. The heat might soften the threads on the pan or cook the gasket if it is too close to the plug. Just my opinion.


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Old 12-06-2015, 05:51 AM   #25
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Step one is a "6 point" 22 mm socket. The standard 12 point ones give less contact to the flats of the plug.

Then if you have an impact gun, try it, otherwise get the socket on straight, keep it straight and give it good fast hard pull.

If that don't work, a little heat on the threads around the plug may help. Maybe just running it at high load will help.

Don't heat the plug, you don't want that expanding.

If all else fails, suck the oil out. This is done on marine engines and generators regularly.
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Old 12-06-2015, 09:40 AM   #26
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Onan 7.5 Gen Set

I ordered this today for my electric impact drill:
Name:   ImageUploadedByiRV2 - RV Forum1449416390.717564.jpg
Views: 186
Size:  23.0 KB
What do you think about using a bolt extractor like this?
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Old 12-06-2015, 09:45 AM   #27
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It's most likely a 6 point socket, that good.

If it don't turn with the gun, turn the socket with a pipe wrench, and use the gun at the same time.
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Old 12-06-2015, 09:48 AM   #28
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Actually it's an extractor. Inside looks like this:

Name:   ImageUploadedByiRV2 - RV Forum1449416826.484290.jpg
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I've been using a hex 22mm deep with the breaker bar and no results. Don't have any experience with this type of socket.
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