[s-cars] removal of oil drain plug

[Jon Boultinghouse]

Dan, I just got a '95 S6 and the same thing happened to me about a month
ago.  It was driven from colorado to me in texas, and the oil was about as
old and black as could be.  I was running out of options when I went to 4
oil change places and no one could get it off.  Finally, i went to a mom and
pop service station, and said, look,  i need my oil changed, do what you can
to get this damn thing off.  Thinking I was about to buy an oil pan anyway,
they used a a file to file the nut into a square, a pip wrench with a pipe
connected to the handle for more leverage, and an air chisle... it twisted
off with no problem.  The air-chisle was the key.  Just be careful, the oil
pan is aluminum and soft, and the plug is steel... thus the reason the thing
gets lodged in there in the first place.  No internal thread damage at all,
good luck, it was a b%#ch... Jon    '95 S6



>From: "James Murray (LMC)" <James.Murray at ericsson.ca>
>To: "'CyberPoet'" <thecyberpoet at cyberpoet.net>,s-car-list at audifans.com
>CC: dslagle at zoominternet.net
>Subject: RE: [s-cars] removal of oil drain plug
>Date: Wed, 2 Apr 2003 19:15:04 -0500
>
>Oooh... ignore my suggestion of heating it then! yikes....
>
>-----Original Message-----
>From: CyberPoet [mailto:thecyberpoet at cyberpoet.net]
>Sent: Wednesday, April 02, 2003 7:09 PM
>To: s-car-list at audifans.com
>Cc: dslagle at zoominternet.net
>Subject: Re: [s-cars] removal of oil drain plug
>
>
>Dan,
>
>ran into the same problem on our '93 Audi 100 about three
>months ago. Ended up needing three guys, a six foot breaker
>bar and a chrome-alloy close-ended wrench (23 mm? 26 mm?
>Wasn't an american size at any rate). I don't know who put
>the plug in last (PO or a garage that did work for him),
>but damn it was a PIA! Anyway, I'd suggest making sure the
>engine is as cold as possible -- the bolt expands outwards
>when warm, and the oil-pan retainer of the bolt expands
>inward when warm, and the copper washer expands between the
>two when warm, and all three conspire to help keep the bolt
>tight when warm/hot. Icing the plug might help, and we hit
>it several times with spray brake cleaner before removing
>it to make sure no oil was complicating the grip issues on
>the outside of the bolt.
>
>In theory, you could affix a strong wrench in the right
>spot and then start lifting the end of it with a floor jack
>-- the weight of the engine should wrench the bolt free. If
>the head is really torn up, get the biggest pair of
>vice-grips you can afford and try that.  Similarly, you can
>cut the head of the bolt to take a impact driver.
>
>Have the replacement FUMOTO drain plug on had, along with
>two or three brass/copper washers for once you get your
>original plug out; you'll never go through the pain again.
>
>Now my best suggestion: if you didn't just recently
>purchase the car and know who put the bolt in last, take it
>back there and make them take it out (along with a stern
>lecture about foot-lbs and torque specifications).
>
>One word of warning: it is possible, in theory at least, to
>rip the cast aluminum oil pan if too much force is
>transfered through the bolt (unlikely, but possible, and I
>warned you :P ).
>
>Good Luck
>=-= Marc
>
>PS - damn to hell whoever thought up the idea of using a
>stronger metal plug (brass/bronze/steel) in a weaker metal oil
>pan (aluminum). Curse the Idiots. Including the ones over
>at the Suzuki factory who designed my motorcycle...
>
>Dan wrote:
>
> > Dear Listeners:  The oil drain plug on my 95 S6 will not unscrew. After
> > several attempts lying on my back and partially defacing the plug,
> > I took it to a service center where two mechanics and a breaker bar
> > could not break it free.  They suggested an Audi dealer; however,
> > before I do that, are there any suggestions from the List?  I
> > appreciate
> > BTDT experiences, as well as any information regarding a type of
> > socket or wrench for partially stripped bolt heads that was mentioned
> > on the List awhile ago. It might have been a Sears product.
> > Thank you.
> >
> > Dan
> > 95.5 S6
>
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