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Ozzie · Posted: Wed Jan 17, 2007 1:02 pm Post subject: F*&^<(*- Sump plug.

I have tried every tool in my arsenal and the sump (engine oil drain) plug wont come off.
Sockets, box spanners, breaker bars, fit all spanner (snapped), monkey wrench.

Ideas? Anyone?
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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

JakeFrame · Joined: 28 Feb 2006 Posts: 93 Location: Ohio zip- 43501

Sounds like its stripped....have you tried a pipe wrench? Vise Grips? A punch?
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1976 924 Automatic- Body Only
1977 924 4 spd Red~For Sale~
1977 924 4 spd Yellow~For Sale~
1977 924 4 spd
1992 Mercedes 300e 4MATIC

geddes66 · Joined: 10 May 2003 Posts: 129 Location: Bakersfield CA

If it really stay this stubborn, drill it, tap it and install a smaller plug in the bigger plug.
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The Porsche is now my son's, my car is cooler, slower but cooler.

steeny · Posted: Wed Jan 17, 2007 1:46 pm Post subject:

as long as the nut itself is still ok, have youu tried a rattle gun?

i'd be driving to the local mechanics with a couple of stubbies, and get one of the mechanics to put the 3/4 rattle gun on it. then tighten by hand, and drive home to do your oil change

other than that, i have no idea.
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1978 924 N/A
she's gone.....

931Tony · Joined: 15 Jan 2007 Posts: 40 Location: Lawrence, KS

Maybe you could post a pic? So we can see if it looks like it may be welded or something?
Also... not trying to be a smartass but because its a possibility. Righty-Tighty, Lefty-Loosy? Counter clockwise is off.

Thanks! I'll help if I can!

Ozzie · Posted: Wed Jan 17, 2007 2:11 pm Post subject:

I used this so far and have rounded it off a little more. (it was rounded off before I started)

Ozzie · Posted: Wed Jan 17, 2007 2:14 pm Post subject:

steeny · Posted: Wed Jan 17, 2007 2:16 pm Post subject:

only prob is how well it will drain oil from the smaller opening (ie the new tapped hole size) and its a mean bolt too as i remember. not sure how you will go drilling it from under the car with a handdrill and still being tapable and able to hold oil.

you could always helicoil it out and replace it with one of those pretty oil drain valves like chrenan has....
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1978 924 N/A
she's gone.....

Ozzie · Posted: Wed Jan 17, 2007 2:25 pm Post subject:

As you can see the nut is mangled so I am thinking of drilling next to it where the arrow is pointing.
Anyone know how thick the wall is there?

_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

Lizard · Posted: Wed Jan 17, 2007 4:33 pm Post subject:

I am afraid that the wall there is not thick enough imo for what you are thinking.

I would suggest a propane torch to heat up the aluminum (it will expand quicker than the steel releasing the grip) then I would hit it very hard dead on the end with a hammer, this will compress the crush ring and hopefully make the bolt really loose. I would then use the pipe wrench to try to turn it again.

the other thing I would try is to take a file, not a grinder, and file a new bolt head on there, it will be smaller granted, then make it a very tight fit to the closest wrench you can and tap on the end of the wrench with a hammer to loosen.

just to confirm though you are turning it the right way correct. (sorry have to ask)
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3 928s,

rusto · Joined: 06 Jan 2007 Posts: 11 Location: Portsmouth, UK

Have you tried a chisel? Use a sharp one to make a nick in the outer edge of the plug and a less sharp one to tap the plug round. If it doesn't come out and you have to drill into the plug, the sump should really be off the car or you're chancing swarf in the engine - in which case it might be easier to just fit a used sump.

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

+1 on the torch. I would be hesitant to be drilling anything.
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WeiBe (1987 924S 2.5t) - 931 S3

Mike924 · Joined: 12 Aug 2004 Posts: 2601 Location: IoW UK

I would go with the torch first.

Don't try anything irreversible until you've exhausted all the alternatives.
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1985 Porsche 924 'Lux', Kalahari Beige (my ex)
1993 Porsche 968 Coupe, Midnight Blue, 6 spd

'There is no substitute for a little grease under your fingernails.' - Chrenan, 924board.org

Joes924Racer · Posted: Wed Jan 17, 2007 6:41 pm Post subject:

You know a stubby they meant for removing
rounded bolt heads if so little heat and one of
those. TheoneI recieved from porsche doesnt
havea bolt head but a bigallen wrench hole.

Good+ luck those can be tough theres a another small bolt up higher you could open it doesnt let out all the oil.
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1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

had the same problem...i grinded the old oil cap head and used a smaller but more accurate and bigger tool...i did this with a hot engine...and with enough force it came off.

good luck.

OT: could you post some pics of your rear hatch ? i see its darken but..i'm curious how did you do that...with pieces of foil or... ?
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