[s-cars] Help!! Evil drain plug will NOT come out

[Robert Rossato]

Via use of a proper fitting 6pt socket (never, ever use a 12pt) and
1/2"dr, 24" breaker bar I've always been able to remove the drain bolt
with absolutely no fuss.  Car needs to be on a set of ramps, or jack
stands, to have suitable clearance for the breaker bar.  An 18" bar
would suffice but it's oh so easy with the 24".  

In any case, at this stage of the game for you if all the other tricks
of hammering a smaller socket on, or using one of the Craftsman bolt
outs hasn't worked, I would recommend finding someone with a MIG welder
and welding a suitably sized 1/2"dr socket, or a large bolt head, to the
end of the drain bolt.  You'll have to grind away the chrome from the
sacrificial socket prior to welding to have any hope of getting a good
weld.  Get a nice perimeter weld, at least as far as you can reach.  May
have to lower the starter cable tubing to gain clearance (two 10mm
bolts).  

WARNING: Before doing any welding be sure to disconnect the ground cable
at the battery so you don't damage the ECU.  May even want to disconnect
the ECU itself to be sure.

After welding the socket loosen the drain plug with the aforementioned
breaker bar.  

Bob

> -----Original Message-----
> From: s-car-list-bounces at audifans.com 
> [mailto:s-car-list-bounces at audifans.com] On Behalf Of Edward
> Sent: Sunday, January 16, 2005 10:23 AM
> To: s-car-list at audifans.com
> Subject: Re: [s-cars] Help!! Evil drain plug will NOT come out
> 
> 
> Hmm, I might just be desperate enough to try dropping the pan, if it
> isn't too hard.  Any BTDT?  Bently mentions "Turn crankshaft until two
> securing bolts (arrows) of oil pan are visible." as a step to do this.
>  How does one manually turn the crankshaft on this engine?
> 
> Got a few more ideas from surfing audiworld till the wee hours last
> night (good suggestion!).  Looks like hack saw out the copper ring,
> hand file the bolt head into a smaller bolt size and torch the crap
> out of the pan are my next options.  But if this fails, the pan
> dropping will have to be my next course of action.
> 
> Ed