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tlecronier's avatar
tlecronier
Explorer
Jun 03, 2013

Oil drain plug rusted in and stripped

What I thought would be an easy job has turned in to a nightmare. I went to change the oil in my Onan QD 7500 Generator and the oil drain plug would not budge. I used penetrating oil and heat. After the bolt head stripping with a socket, and then stripping more using my Craftman bolt-out set and then finally vice grips, I now have a pretty well rounded bolt head that will not come out. I have a 2004 Monaco that I purchased last August. I am not sure if the oil plug on the generator has ever been removed.

Any ideas out there? I am at a loss.

Thanks,
Todd

24 Replies

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  • tlecronier's avatar
    tlecronier
    Explorer
    Jun 03, 2013
    I really do not want to drill it and re-tap. I have never done that before and do not want to learn on my generator. LOL!

    I am also worried that if I finally get a "good" grip on the bolt and really torque it, it may crack the pan.

    I never knew such a device existed (oil extractor). I have been looking at them online at Harbor Freight. I think that is what I will probably do. Thank you so much for the help.

    Would anyone trust Camping World to get it out without causing more damage?
  • midnightsadie's avatar
    midnightsadie
    Explorer II
    Jun 03, 2013
    TPI has a great idea I do this on my boats.. then I,d drill the plug and have all my gear ready, heat the plug and go for it. might even smack it good with a hammer after heated.
  • tpi's avatar
    tpi
    Explorer
    Jun 03, 2013
    If it were mine I'd try my vacuum oil extractor. The tube feeds in the dipstick hole and if it goes to the bottom of oil pan you're good. They're used a lot on boat oil changes where there is limited clearance in the bilge. Best with the oil warmed up.

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