2004 GTX Supercharged Oil Plug on lower case stripped help please

[Grigg]

anyone run across this before, The moron who worked on my Ski before I bought it must have stripped out one of the 8 Torx Covers on the bottom case. The Plug had silicone all over it is there any way to repair this besides a new case ??

 

[Coastiejoe]

Drill and heli-coil it.

 

[Grigg]

They make Heil coils that large? Do you know what size and thread it is

 

[Coastiejoe]

Pull an original bolt and take it with you to get the correct size and pitch thread. You'll need a drill and tap unless you get it as a kit

 

[Grigg]

They don't make one that big that i can find its a M30x15

 

[Grigg]

Found one only problem is its cheaper to buy a used case lol

 

[Coastiejoe]

Wow. $200 and higher is all I could find. A bit shocking.

 

[ORION '95 Speedster]

Been there. Buy an "oversized" drain plug. They are self tapping. They work very well. You apply grease to the plug before boring the new threads. The grease traps the shavings that are cut cut by the new plug.

 

[ski-d00]

I've heard that Loctite Form-a-thread will work but I haven't tried it. Seems like it would since it only has to withstand a little heat and seal oil. I have a bunch of extra plugs if you need any.

 

[ORION '95 Speedster]

I get a steal of a deal on a new race quad once. It was worth $6,000 and I paid a few hundred. The reason it was cheap was because someone had over tightened the drain plug and it stripped "in". It would rotate both directions freely, but would not come out or tighten up at all to seal the hole. The dealer said it needed a whole new engine case ($5k) , so the owner sold it to me cheap. I put a pry bar under the lip of the plug and backed it out. The threads were shot obviously. I went to the auto parts store and bought an "oversized self tapping drain plug". You put grease on the tip, and thread it in 2 turns then remove and clean the grease off (with shavings). Then re-grease and tread it in 4 turns, remove and re-grease, thread it in 6 turns and so on. It actually self tapped new threads right into the case, and prevented shavings from entering the case. After it seated all the way, it sealed the case perfectly. I have changed the oil many times with that plug and it has held up very well. No issues at all.

Pic:

 

[ORION '95 Speedster]

The tip is cut like that to assist in the cutting process, and to help trap the shavings in the grease.

 

[ski-d00]

I used one on a Jetta stripped drain plug years ago and it worked well. However, the plug with the stripped threads is about 1.25" in diameter and I've never seen one that large.

 

[Chester]

anyone run across this before, The moron who worked on my Ski before I bought it must have stripped out one of the 8 Torx Covers on the bottom case. The Plug had silicone all over it is there any way to repair this besides a new case ??

Can you get the plug out? The early ones were hard to get out and you would strip out the torx hole unless you used heat. You can just drill it and use an easy out. The threads in the block should be OK.

I don't think the posters in this thread realize that you are talking about these plugs.

Chester

 

[sampuppy1]

Can you get the plug out? The early ones were hard to get out and you would strip out the torx hole unless you used heat. You can just drill it and use an easy out. The threads in the block should be OK.

I don't think the posters in this thread realize that you are talking about these plugs.

Chester

I had four of these little bastards on my Grand Prix transmission case that I stripped trying to remove them to rebuild it. I drilled the holes round and pounded a slightly larger Allen bit socket in them and they all came loose. I went to the junk yard and found normal bolts of the same size and thread pattern and put them in instead. There was no reason for the torx bolts. There was no clearance issues. Just be careful when drilling the hole. Go too deep or large and you can break the head free from the bolt shank. And that's a whole new barrel of shenanigans.

 

[ski-d00]

The OP is not talking about the torx fitting stripping out. He is talking about the threads in the block stripped out from the aluminum plug which I have seen before. That's why someone put silicone on it and why he thinks he may need a new block.

Just use Form-a-thread as I mentioned above. It should work fine. The only thing that plug does is seal oil.

 

[Chester]

I had four of these little bastards on my Grand Prix transmission case that I stripped trying to remove them to rebuild it. I drilled the holes round and pounded a slightly larger Allen bit socket in them and they all came loose. I went to the junk yard and found normal bolts of the same size and thread pattern and put them in instead. There was no reason for the torx bolts. There was no clearance issues. Just be careful when drilling the hole. Go too deep or large and you can break the head free from the bolt shank. And that's a whole new barrel of shenanigans.

They are not bolts, they are aluminum plugs. See my picture.

Chester

 

[Sea Dood]

That shitty yellow 3M threadlocker they put on those plugs is a pain in the ass. It doesn't shatter like Loctite when it gives, it is more gummy and it can cause threads to gall. I only put about 50 ft lbs on them when removing, if they won't budge, I get out the MAPP torch and have at it. Once you heat them up good, they come right off.