stripped oil pan, 2000 dodge caravan, 2.4L

[peteinva]

I was losing a lot of oil after last oil change, had to put in about 2 quarts between change. I noticed when I changed the oil that the drain bolt was spinning pretty freely, but was able to come out. The spray of oil underneath made it pretty apparent it was the source of the leak. So I went to Advance auto and got a replacement drain bolt, the self tapping kind that's a plus size. Seemed like a pretty good solution. So I install and I'm feeling pretty good, as it cut good threads and seemed to go in well. The next morning, there's a pretty good puddle of oil underneath the bolt. I proceed to tighten, but nothing more. So upon closer inspection, I notice that the bolt that was suggested to me was about 1/16" too long and touching the inside pan and not seating against the drain hole (grr...). Well, it looks like it's still leaking oil and it's stripped on a 14+mm hole instead of a 14mm hole now. Any suggestions short of a new oil pan? Is there a product that will tap an even larger hole and is sure to fit and not be just-too-long (ie., 16mm self tapping drain plug w/ piggyback plug)?

[MagicRat]

I've been there before. I had a Mustang with an oversize drain plug. When that strips, the next-larger size simply will not fit.

It's easy enough for someone with a MIG welder to weld-on a nut over the drain plug hole, then use a bolt as a plug.

Another option is to get a brass fitting (the kind with pipe thread on the inside and out) Hopefully one can get one that fits reasonably snugly in the hole. Spray the hole down with brake cleaner to degrease the surface, then mix-up some JB-Weld epoxy, cover the outside brass threads with it and screw it in.
When it dries, you should be able to use a pipe thread plug which screws into the brass fitting....... and that shall be the new drain plug.

Yes it is a bit half-assed but it worked for me and is cheap to do.

[Alphabravo]

If its only 1/16" too long you could probably use a brass washer as a spacer. That should snug it up. I've seen that before, I've even seen two washers used that way. Good luck.

[peteinva]

quick update: My mechanic showed me the helicoil that would have worked in smaller stripped hole, and all would have been well . Anyway, he was able to work on a bolt and weld in place. The drain pan gasket was leaking pretty good too. So the bolt and new drain pan gasket are holding in the oil reeeaaaaly well. No more worries about the engine running dry! Only now it will need topsider vacuum pump for oil changes, which he has. Should work for a few more years. I'm happy.

Thanks for the suggestions.

[Alphabravo]

I'm glad it worked out for you. I am surprised that your mechanic didn't suggest a junkyard oil pan since he dropped the pan anyway to replace the gasket. That way you would not be forced to have to pump the oil out every time you need an oil change. Just my opinion.

But then again it might have been expensive, I don't know what junkyard oil pans go for.

[jd-autotech]

i have seen universal expanding boat plugs used in this type of situation, dont laugh it works