Date: Wed, 27 Apr 2005 12:36:59 -0700
Reply-To: James V <tornadored@EARTHLINK.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: James V <tornadored@EARTHLINK.NET>
Subject: Re: Oil drain plug
In-Reply-To: <1df.3ac3cb01.2fa12747@cs.com>
Content-type: text/plain; charset="US-ASCII"
On 4/27/05 10:35 AM, "Jim Comer" <Shadesof2worlds@CS.COM> wrote:
> I just bought a 84 gl and everything was great until tune up time ..I found
> that the oil drain plug is stripped..Is there anything i can do to fix it
> besides tearing the motor down??
I take it the drain plug HOLE is stripped, yeah?
I just went through this just before a 10 day vacation. There's tons of
stuff in the archives about this as it's a common problem. There's one post
in particular that outlines the options well... But in a nutshell the common
repairs, IIRC, are:
a. rethread for a larger drain plug
b. rethread and install helicoil for standard plug
c. rethread w/ Time-Sert type kit
d. rethread w/ spark plug hole repair kit
I heard mixed reviews about the first 2 options, but the latter 2 seemed to
work well for most. Both are basically methods to tap the hole to accept a
threaded insert into which the drain plug goes. Ideally I think I would
have chosen the TimeSert (http://www.timesert.com). Their threaded insert
has a collar that looks like would seat well and provide a new smooth
surface for the plug flange to seat against. The inserts maybe be available
for the stock 14x1.5 plug. But since I needed it immediately, I went w/ the
spark plug kit, since they are readily available at most FLAPS.
The $30 kit ("Perma-Plug"), intended of course for spark plugs, seems to
function equally well for the drain plug. It includes a tap, threaded
inserts of varying length for a 14x1.25 spark plug, and punch tool to seat
the insert. You will need to replace the stock M14x1.5 drain plug w/ a
M14x1.25 (The finer threads may actually be better suited to the aluminum
case?). Pay attention to the size of the gasket flange of the new plug as
it is likely bigger than stock and may present fitment issues in the
recessed plug hole. The plug I found worked fine. You might also want to
pick up several quarts of cheap oil for flushing and oil change.
Procedure is easy following the included instructions. No drilling
necessary. The tap actually has 2 sets of threads - the first smaller set
is presumably 14x1.25 and helps to align itself w/ the current hole. Even
though these threads are finer, it still worked well in my stripped 1.5
hole. Then, further up on the tap are the larger threads which actually tap
the hole for the new insert.
I tapped slowly, backing out after each turn or two to release shavings and
continually added oil to the filler which also helped drain out the bits
along the way. Messy.
Clean hole and insert the threaded insert (w/ some hi-temp silicone) until
flush, then use the included punch tool to whack the end a few times which
seats/secures the special knurled ends of the insert into the hole (makes
sense when you see it).
I also used a dremel and smoothed out around the hole a bit for a better
seal.
Use a new fiber or crush washer and install the new 14x1.25 plug. One more
oil change for good measures and your good to go. Haven't had it installed
long, but it is holding perfectly so far. Took me a couple hours, so it's
probably a 30 min. job.
James V