oil galley plug heavy weeping (... Oil leak) 1970 Stock Beetle

[J-Gaz.]

I have had the unfortunate experience of building my motor only to discover that one of my oil galley plugs was not seated correctly in my new case.

I've been living with some epoxy over the plug to slow the leak, and it has worked some. But it's still leaking.

I think I already know the answer, but thought I'd ask just in case I missed something.

Here's the question:
Is there any way to pull out and replace the plug without having to tear down the motor?

My understanding is that it has to get drilled out, and that would put a bunch of metal shavings in my case.

So the only way to do it is to disassemble the entire motor, drill, replace, and rebuild.

Am I missing a potentially easier solution?

Thank you
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1970 Beetle | Basically Stock 1600 SP

[RWK]

Depending on which plug it is, you could try peening around the plug with a center punch, as a FIX, the solution is as you said, disassembly and drill and tap.
Never tried it, but the plugs are tapered cups, it may be possible to drive it in a bit more (1/16-1/ and it might seal up in new part of hole dia. make sure you have a punch that fits it accurately, then possibly new epoxy over it?
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73 Type 181
63 Type 113
63 Type 261- 428 071
62 Type 241-378 025 178 530

[J-Gaz.]

[raydog]

You say that the plug is "a little too far driven into the case." Is it possible the case could develop a crack at the threaded port?
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Come on, It's not rocket science. KISS

[74 Thing]

Post a photo

[viiking]

I assume you are talking about press in plugs?

This is a backyard hack but I’d consider the effort and money that a pull apart and reseal is going to cost.

I’d be willing to just drill a small hole with a greased up drill bit. Drill through then reverse the drill to pull out most of the big bits.Screw in a sturdy self tapper and then pull it out with a small puller. You’d have to rig up some washers or something for the puller to grip onto. Of course if the plug is not too shallow you wouldn’t have to drill all the way through.

If the screw comes out and you have to drill bigger then I still would not be too worried about too much swarf entering. The level of oil in the galley should push out the garbage.

You could get all clever and add some thinner flushing oil/kerosine to the engine to build up the “head pressure” for added insurance. Of course you would be changing the oil anyway.

If you can determine that the galley is on the pressure side you could crank the engine before reinstalling a new plug and force any crap out for sure.
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1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[J-Gaz.]

[johnnyvw164]

You could just try driving in a very short wood screw, with the hopes that will expand the plug a bit into the hole.

Desperate times call for desperate measures...

[KTPhil]

[Multi69s]

If its at the rear of the engine, jack the rear end up has high as you can so that there is no oil resting against the plug. Spray the area with carb cleaner, then put a sanding drum on a dremel and sand the case and plug until both are clean. Spray it with carb cleaner and blow or wipe dry. Watch for anything seeping out. If it remains dry, cover the area with JB Quick Weld.

This will work as long as there is no seepage at the plug. There is virtually no oil pressure working against the JB Weld, it is more of a seepage leak.
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69 road Bug 2110
73 Squareback - 2L, T4, Automatic W/ AC
Gone, but many fond memories 69 Baja Bug 2010 - 5 Rib Bus Transaxle
Gone but not forgotten 72 Baja Bug 2010
My builds
T4 into Squareback http://www.thesamba.com/vw/forum/viewtopic.php?t=458944&highlight=
Auto Trans Rebuild http://www.thesamba.com/vw/forum/viewtopic.php?t=516066&highlight=
AC in Squareback https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

[J-Gaz.]

[J-Gaz.]

Feb 2023 I took the motor to an engine builder near me.
John Morris Race Engines - Port Orchard Wa. / Gorst

He called when disassembling to let me know that the case nuts came off WAY too easily. The case half looked oily prior to disassembly and didn't notice anything around the oil galleys plugs.

He also noticed an absence or extremely thin sealant on the north end of the case behind the flywheel...

Regardless. Had him go through the motor, full-flow, and reseal it. Driven it twice, no leaks 🤞
Hoping it stays that way for the rest of summer.

He used Curil T for the case halves.

I'm going to have him do the valves and check torques after I get some miles on it 🤙
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1970 Beetle | Basically Stock 1600 SP