Sump plug blues

Post by **fraggers** » 27 Sep 2008, 19:42

So After getting my Van last week I ask the fella i purshed it off has it had an oil change he says why yes, only 500 or so miles ago. No problems thinks I. But i always like to know when the oil has been changed for sure, and as its a small say 1hr (at most) job. i decided to do it last night (I work shifts and have a nice workshop and can wangle some time to do small jobs) so i remove the sump plug............... I bet you all know whats coming now, It came out really easily (far too easily) and of course after i drained the oil and put the plug back in and refilled their was the drip drip drip of oil from the plug. So what to do, i am at work have no more oil, I can't leave the plug as it is... Its just not right you know. I get a lift home and my home boy russ the mega mechanic is at work on the oppisite shift. I tell the tale before going home. He then calls me at 15:00 "go get oil and filter got a solution." When i return to work with the parts, the van is back in the work shop russ is underneath. This is the solution
[img:512:386]http://lh4.ggpht.com/bandiphotos/SN6G5i ... 2/sump.jpg[/img]
The sump plug hole is now tapped out to 16mm (standard), there is lots of meat in the sump its just not really deep but pleanty for the thread.

The 16m allen (caphead) bolts looks real ugly underneath. I may get a picture later but its a great tight fit along with sealing washer the jobs done, and as the the thread pitch is 2mm the threads are deep in the sump and hopefully less likely to strip...

what do you think....................

ahh is this in the wrong forum.......

edited by mocki to make picture work

Post by **fraggers** » 27 Sep 2008, 19:44

cleaned out as image now available

Post by **fraggers** » 27 Sep 2008, 19:52

can't delete it

Post by **fraggers** » 28 Sep 2008, 02:16

A few handy hints if you have to tap your sump plug out.

first
DONT PANIC

16mm does not need any drilling
Use a Tap wrench as you can see if the thread is being cut square easier
Try, If possible use all three taps of the set as the lenth of the thread that will be cut in the sump is not that deep so the final or plug tap will ensure that the thread is the right depth at the start of the thread.
Do the job when there is still oil dripping from the sump. this will
1. Act as a cutting fliud to ensure a nice clean cut thread
2. Wash the swarf away from the sump as you cut the thread
When fitting a non fine Thread plug (like mine) use PTFE tape (3 wraps around should me more than adequate)

A little more info.
When the old plug was removed the hole in the sump was inspected there is quite a lot of metal to cut the thread, so although it is a scary process it is not too troublesome.

If at all possible i would recommend using a 14mm helicoil and not going for the 16mm socket head Mod I carried out. This is because you can cut away metal on the sump but cant put it back. I was in a position that left little or no other option. Along with the fact that all the equipment and parts to do the mod I carried out were at hand and free.
That said this has worked out really well. Although I will always have to bear in mind the lowest part of my van is now the sump plug. I may endevour to to make some sort of guard

Post by **fraggers** » 28 Sep 2008, 02:38

Here is the new 16mm cap head in place in the sump.
I have used a sealing washer normally used on high pressure guage fittings in industrial processes
[img:720:540]http://lh3.ggpht.com/bandiphotos/SN7rnX ... 0/plug.JPG[/img]
from this it is obviouse how ugly it looks and how far out it sticks below the sump.

Hope this post is of use to someone.