Goddam Porsche and Aluminum Oil Drain Plugs

[unclebilly]

What kind of idiot makes an aluminum oil drain plug with an Allen head?

I tried pounding in the #45 Torx, then a triple square, and ground a square screw extractor so it would bite…

What type of screw extractor would you suggest. Remember this is aluminum so not going to get a good bite.

[unclebilly]

I might try drilling a 1/8 or 3/16 hole in the flat part and the. Using a pin punch to spin it. Possibly with an air hammer.

[GH85Carrera]

My wife's Macan has a plastic drain plug. The oil change "kit" comes with a new one each time. One filter and O-ring, and the plastic drain plug.

What model of Porsche has that aluminum plug?

[ninelevenick]

I have been where you are twice, and both times my handy screw extractor I bought at HF worked like a champ. Easy peasy.

[ninelevenick]

[rfuerst911sc]

Can you grab the perimeter of the plug with needle nose vise grips ?

[Shaun @ Tru6]

I get a new Al plug for my Cayenne every 5K oil change from FCP. To get that out I would use an air chisel on the outer edge. One burst will break it free. Short of an air version, try a chisel and hammer, maybe small taps to dig a wedge into the rim and then harder strikes to turn it.

[908/930]

I think drilling two shallow 1/8 holes near the outer diameter and using some form of pin wrench should turn it.

[ninelevenick]

I forgot to mention that I used the above extractor set to remove buggered up drain plugs from both my Cayennes.

[1990C4S]

If anything is close to turning it add some valve grinding paste to the tip and try again.

Cut a slot with zip cut, hammer on the slot with a good quality screwdriver, or the air chisel.

Next step for me would be a square screw extractor.

https://www.amazon.ca/Extractor-Straight-Household-Professional-Electrician/dp/B09TD7ZWFJ/ref=sr_1_5?crid=4TXN4G8O0VUU&dib=eyJ2IjoiMSJ9.sYFrsXk94jlpqmWRpykJE4P9PG-yvltTqDBzWSTQVq9PWiVIf0P3XzooKDJtoIWuLr_sBVpH7UYyB v2LECyEiLO98aRQ6GmWmM2-RRCiDM010xaGMa6343h58Wtd96n8vX3ioPFTmr7ZA6fzQoBpeb-5in699rPm82J66QoklO1hpx7ItWsb9GOrtjYsU7p22mNfQBUon 36ciIXQt6fJuWv2xIxzcjwl00EaxyzMiNfyQ5uVWUvH-2aCl0i9PCZjqPRaTZ93DJaTm4Wvp6-YFXZBszvptRr1qPX5e_xbQwU.ti2dmzpTjphhxuecA654Rb1cI PUhLbDxOWOYXQbR_NA&dib_tag=se&keywords=square+easy+out&qid=1721321213&sprefix=square+easy+out%2Caps%2C79&sr=8-5

Then a threaded screw extractor, then a die grinder to remove a slot right up to the case thread...then flush it well.

[speeder]

How on earth did it get that way? I agree that aluminum isn’t the best choice for a plug but I also can’t imagine how the correct size Allen wrench would strip it(?) Who tightened it? So many questions…

As for getting it loose, a chisel is the only correct answer. The good news is that aluminum is soft and it will dig in easily, in fact it might dig for too long before it turns and damage the pan if you’re not careful. An air chisel is a bad idea unless you want to replace the pan as well, even a small cold chisel must be done carefully but it will work.

Get a new plug and washer and don’t over tighten it next time.

[1990C4S]

Loctite teflon paste is also a decent anti-galling sealant.

[Shaun @ Tru6]

Originally Posted by speeder

How on earth did it get that way? I agree that aluminum isn’t the best choice for a plug but I also can’t imagine how the correct size Allen wrench would strip it(?) Who tightened it? So many questions…

As for getting it loose, a chisel is the only correct answer. The good news is that aluminum is soft and it will dig in easily, in fact it might dig for too long before it turns and damage the pan if you’re not careful. An air chisel is a bad idea unless you want to replace the pan as well, even a small cold chisel must be done carefully but it will work.

Get a new plug and washer and don’t over tighten it next time.

I think we can trust UB to not put 125 psi through an air chisel. And to start with low pressure like 30 and move up. 40 is likely more than sufficient and trigger pressure is measured, that is pull a little, get 20 of your regulator set 40 psi, squeeze more for 30,,, 40. I have set well over 1000 aluminum rivets in 911 fan hubs at 90 psi and decklid grille rivets at 10 psi which is virtually nothing. 10 psi is like tapping that drain plug with a screwdriver handle to the beat of your favorite song. People with skills like UB, based on his previous postings, an air chisel is the tool of choice for this job, just start low and move up.

[fastfredracing]

Originally Posted by speeder

How on earth did it get that way? I agree that aluminum isn’t the best choice for a plug but I also can’t imagine how the correct size Allen wrench would strip it(?) Who tightened it? So many questions…

As for getting it loose, a chisel is the only correct answer. The good news is that aluminum is soft and it will dig in easily, in fact it might dig for too long before it turns and damage the pan if you’re not careful. An air chisel is a bad idea unless you want to replace the pan as well, even a small cold chisel must be done carefully but it will work.

Get a new plug and washer and don’t over tighten it next time.

I concour that a chisel is most likey to correct answer . An air chisel would work, but you would have to have surgical like precision not to ham fist it all up and end up in the pan.
You could try the next bigger size torx and pound it in there first. Sometimes the extra flutes/splines will get a good grab on it .

[pwd72s]

Try the rubber band trick with a Torx bit?

[908/930]

Chisel? You guys are butchers.

[speeder]

Originally Posted by Shaun @ Tru6

I think we can trust UB to not put 125 psi through an air chisel. And to start with low pressure like 30 and move up. 40 is likely more than sufficient and trigger pressure is measured, that is pull a little, get 20 of your regulator set 40 psi, squeeze more for 30,,, 40. I have set well over 1000 aluminum rivets in 911 fan hubs at 90 psi and decklid grille rivets at 10 psi which is virtually nothing. 10 psi is like tapping that drain plug with a screwdriver handle to the beat of your favorite song. People with skills like UB, based on his previous postings, an air chisel is the tool of choice for this job, just start low and move up.

Is he the one that over tightened the plug in the first place, then pounded in a Torx bit and then a triple square and then a screw extractor? Skills like that?

At any rate, an air chisel is the wrong tool for the job. A hand chisel is plenty of impact and less likely to cause more damage. As my old man once said when one of my friends wanted to hire him for a DUI case, "you're using a Sherman tank on a mosquito. Let me give you the numbers for some fly swatters."

[speeder]

Originally Posted by 908/930

Chisel? You guys are butchers.

Oh, he definitely butchered the plug. That ship has sailed. Now it's a matter of getting it out.

[911boost]

Polaris does the same thing, uses an aluminum plug for their differentials. I have done the exact same thing UB did using the correct sized allen and following all of the proper procedures. I used my HF easy out and it worked great.

Needless to say I bought a few extra plugs and just use a new one every time I have to replace the front and rear fluid.

It could have gotten hot from the heat/cool down cycle.

[MBAtarga]

Above idea of cutting/grinding a slot from 1990C4S is what I'd do. Then an impact driver with a big slotted bit.