Drain Plug stripped

[HeyCrutch]

After doing a transmission service on the 2002 EVC today I went to change the oil and filter for the second time and have discovered a pretty big issue.

Background: I first changed this oil in this van last July when I got the van back from its former California home. When I had finished changing the oil at that time, I had a sneaking feeling that the drain plug threads were stripped. I had remove the plug fine, but when replacing the fresh plug and washer, I never got to a point of feeling tight - it was continuing to turn. I didn't "think" that I had over tightened it because I never got to a firm point of resistance. I didn't back the bolt out at that point because I didn't have any inclination to drain the fresh oil I had just filled the pan with. No leaks have occurred in the past 10-11 months since.

Today when I went to remove the drain plug, on the first anti-clockwise pull of the wrench I felt a satisfying "break" of the bolt that one would normally feel when loosening a tightened bolt, but then my fears were realized ... the bolt was spinning but not extracting. The threads must be stripped. I tried using a screwdriver to place some lateral force on the bolt while unscrewing it, to no avail.

No leaks as the bolt is essentially fully seated into the bolt hole. But it's not coming out.

So, in thinking of the resolutions, I've come up with 3 possible solutions:

1) Have the drain pan replaced. This would have the double benefit of dealing with a slight leak on the passenger's side of the pan where the gasket looks to be breaking down. However the part and expected labor to have this done I'd expect to be pretty hefty, especially since I think part of the drive shaft has to be removed to get the pan out.

2) Have the bolt hole re-tapped for a slightly larger bolt. I'm sure this is doable but seems like it could be costly, could be hard to find the right shop to do it, and could still lead to issues in the future.

3) Using an extractor for oil changes from this point forward (or at least until a new oil pan is installed). I'm aware that people use extractors these days, especially on vehicles with plastic pans and plugs, but I'm not certain if the dipstick tube has to be of a certain size to use one of the modern extractors. Anyone have any experience.

Thoughts?


Post-Script Note: It's not VITAL that I actually change the oil right now. The oil has very few miles on it in the past 10-11 months, so all it really has on it is age (again only 10-11 months). Since some suggest that fully synthetic oil can go a couple of years between changes, if not hitting your usual mileage mark, the van is certainly not under any stress in terms of engine oil. I had hoped the change it this summer just to stick with the "at least once a year" schedule, but I'm fine with the oil in the van staying put for now, while I figure out a long term solution. Obviously once I get 5-6k miles on the van, I will need to deal with how to perform an oil change, if the stripped plug hasn't been resolved yet.
_________________
-2003 EV MV Wk - Forest - 51k
-2002 EV Camper - Ghost - 82k
-2003 EV GLS - Fluffhead - 176k

-1997 EVC - 12vVR6 (SOLD 5/2025)

[67rustavenger]

That's unfortunate. Did I read you correctly, the AXK oil pans plastic?
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!
Don't let your bad ideas remain, ideas!

[HeyCrutch]

[kourt]

I faced this problem. The prior California owner had a shop with heavy hands and they stripped my AXK oil drain. It's an aluminum pan.

First I tried this oil drain pan bolt repair kit. It's a good concept kit and would work great if you can get the tap to square properly with the lands/shoulder of the oil pan... but it's at an unusual angle, and I got it off by a few degrees. When the new bolt was snug, it wasn't square with the pan and a little leaking would occur.

I sealed it with RTV and bought an extractor and hated the extractor. End of story there.

So I upped the size again with this self tapping kit (except I used a proper tap and didn't rely on the self tapping bolt). Still leaked, so I sealed the main bolt with a good high temp sealer and use the piggyback, and that works fine.

I recommend the piggyback method I eventually landed on. It takes a lot longer for the oil to drain, but no big deal. This is a good DIY solution.

kourt

[67rustavenger]

The drain plug was likely stripped by a Jiffy Lube or one of those type of shops.
I had a company van many years back. The oil change monkey used an impact driver to tighten the drain plug when he changed the oil and stripped the threads on the oil pan. I didn't notice it until, the next oil change.

If I was in your shoes, I'd attempt to pull on the drain plug with a pair of locking plyers pulling rearward twisting the plug to help engage the threads of the oil pan.
I hope that makes sense.
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!
Don't let your bad ideas remain, ideas!

[HeyCrutch]

[kourt]

Yes, just look at the link. It's a piggyback system.

kourt

[HeyCrutch]

[kourt]

I've found that the crush washer supplied is fine for multiple uses. So don't worry too much about the hex bolt. I've felt good about this solution for my van and would recommend it.

Sorry if I've already said that! I'm grilling steaks and potatoes and drinking dark beer. It's a Sunday night. My wife is taking the EVC to Minneapolis next week for roller derby and it's her first trip in the van by herself, so a bit of a celebration. She would never have driven the old Vanagon, but the EVC is very user friendly. This is what we wanted.

kourt

[HeyCrutch]

The van is at Indian Peaks Auto in Boulder right now having my external transmission cooler installed and a few other regular maintenance items done that I either didn't get to or determined where slightly above my pay grade.

For those who don't know Indian Peaks, they are a great shop that does tons of work on Eurovans (and other European vehicles). Every time I've been there, I've seen no fewer than 5 Eurovans in their care.

They said they are unable to get the drain bolt out (same as me) and said I'll need a replacement oil pan.

Suggestions for sourcing one ... I'll be checking all the usual places (as I'm sure they will when I ask them to), but if any of you have been down the Oil Pan road before, feel free to share your recommendations.

I'll likely use the van for the next two weeks as planned and then return it to Indian Peaks after that so they can do the work (assuming a suitable pan can be located for a decent price).

Thanks everyone!
_________________
-2003 EV MV Wk - Forest - 51k
-2002 EV Camper - Ghost - 82k
-2003 EV GLS - Fluffhead - 176k

-1997 EVC - 12vVR6 (SOLD 5/2025)

[67rustavenger]

Bummer, that oil pan is gonna cost $$$ if you can find one.

When you posted about the stripped drain plug a while back. I searched for a replacement pan.
Check eBay I think I found a few there.
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!
Don't let your bad ideas remain, ideas!

[gesoffen]

My recommendation would be to have the shop drop the existing oil pan, remove the drain plug (should be much easier with the oil pan off the van). At that point, they can drill and re-tap to accept a larger drain plug or helicoil to accept stock/similar drain plug.
_________________
1973 VW Superbeetle (1302) w/ RAT 2270 T4
2003 VW Eurovan Weekender w/ 2.8L VR6 AXK, DYA 5 Spd Manual Conversion

[kourt]

I'm pretty surprised they can't get the drain bolt out. Theres half a dozen ways to cheat the bolt out of the pan--only one or two of them would require tack welding an extension on that bolt head.

I agree with gesoffen--drop the pan and retap the hole. But try to retap without dropping the pan first.

kourt
_________________
2001 Eurovan Winnebago Camper

[Joshwa]

Another oil draining option once you have fixed your pan, or get a new one. I've used Fumoto oil drain valves on a few of my VWs over the years. I've had one on my van for around 5 years now.

https://www.fumotousa.com/cars-pickups-volkswagen-2001-eurovan-2-8l-v6
_________________
93 Weekender TDI conversion (AHU)
93 MV TDI conversion (1Z)
Weekender rear cot
Late model cabin air filter on 93
Euro spec bumper install on 93

[HeyCrutch]

Will be discussing this with them when I pick the van up later ... given that I absolutely have to have use of the van starting this evening, maybe they were hesitant to drop the pan with the uncertainty of which method would be required to eventually get the bolt out.

Either way, the pan has to come down, so the van will be coming back to Indian Peaks in a couple of weeks after our trip. They'll either do as you guys are suggesting, or I'll have a replacement pan for them to use (I've found one online that doesn't required a second mortgage and looks to be in good shape).

That would at least save on their labor and parts to remove, drill out, and re-tap.
_________________
-2003 EV MV Wk - Forest - 51k
-2002 EV Camper - Ghost - 82k
-2003 EV GLS - Fluffhead - 176k

-1997 EVC - 12vVR6 (SOLD 5/2025)

[67rustavenger]

[kourt]

https://www.ebay.com/itm/226881212969
_________________
2001 Eurovan Winnebago Camper

[67rustavenger]

[HeyCrutch]

Thankfully I found one on eBay for $450 after shipping and tax. Chatted with the mechanic that pulled it. Satisfied that I got a deal. Time will tell. That’s $150 less than Indian Peaks would sell me a reconditioned one.

And maybe I’ll find a way to sell the existing pan once it’s freed up and get my money back.

As always thanks for playing.
_________________
-2003 EV MV Wk - Forest - 51k
-2002 EV Camper - Ghost - 82k
-2003 EV GLS - Fluffhead - 176k

-1997 EVC - 12vVR6 (SOLD 5/2025)

[bigfoot_ev]