can you take the pan off? All the way off? if so, take it off and drill it out. Possibly replace with a Fumoto.

 

I'd drop the pan and get a new pan. It's not worth the effort to drill it out IMHO.

 

Yeah I have thought of this as well. Back in the day when I was in mechanic school, we would pound a metric over a standard and chuck the socket and plug in the trash. But, not in this case. See what I can come up with. Probably a new pan.

 

Yeah - i'm sure someone on here has a spare pan. Like doughy.

 

What?
Get these out with nice and sharp teeth:

Close it as hard as possible. A chisel and hammer can also do wonders.
I've seen plenty of seized drain plugs over the years. Always worked

 

Haha, don't think I haven't tried. I may give it another go.

 

I'll holler. Thanks guys.

 

Hit it with an impact if it's not to stripped. Just for a split second though.

From my electronic gismo- Galaxy S6

 

I'd definitely apply some heat that always helps

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Chances are his plug was cross threaded by some ahole with an impact gun.

 

Yup, that's my guess.

 

I'm not saying to ever use an impact on a normal oil change. Actually I teach against it with the techs I train. But a little zip to brake it loose can help alot.

From my electronic gismo- Galaxy S6

 

The hex is stripping? What tool are you using on it? Try a good 6 point socket instead of things that are looser or have smaller contact patches. Getting the right bite on it can make all the difference.

 

6 point socket on half inch impact and be ready for a mess lol. Or you could use an air hammer with a chisel bit to break it loose. Worse comes to worse, take it to a professional if you do not feel comfortable and before it gets any worse. There is a reason technicians spend thousands of dollars on high quality tools.

 

PB Blaster, tons of it.

Then heat. Make that drain plug glow

 

Vice grip used to be my best friend. Now we are through and now I have a new BFF.

http://www.griptitetools.com/

 

The threads on our pans are the same as our park plugs, 14mm. You could use a spark plug as a drain plug, or an oxygen sensor for that matter if you needed a temporary one.
This also means that thread repair kits are readily available.

Get the old one out any way you can. This could include welding a nut to it if you access to a mig welder.

 

Take off oil pan, take oil pan to machine shop that knows what they are doing. Taking the oil pan off is pretty easy.

My local shop charges like $25-35 and they have gotten some badly rounded off stuff. At this point it's cheaper to pay them to get broken off fasteners out vs me wasting a bunch of money on easy outs, reverse drill bits, carbide bits for the dremmel ect.

 

If you don't want to take off the oil pan - break-out the dremel (or small angle grinder) with a cut-off wheel - and do this....

By cutting some meaty flats you will have enough surface to get some decent leverage.

Be careful with impact wrenches as others have done this:

 

That takes some extra special talent!

 

Yikes ^^^

 

I can see a post with the above picture: "Can I use jbweld or something?"

 

For the record, I tried again this past week with vice grips, a slightly smaller "standard" socket :facepalm:, to no avail. Seems that a new pan will be in the works. bloody hell. I will try to grind and use grips again, but that is last time I break knuckles.

 

Seriously, try grinding some flats on the drain plug.
Much easier than dropping a pan.

It happened to me when the shop (I no longer go to) over tightened the drain plug.
I thought 'Oh crap' when the car was in the driveway on jackstands.
But with grinding the flats and a adjustable spanner it came out.

 

Yeah, I hear ya. To be honest, did this a slightly different way back in my rock buggy days of Jeeps by welding a socket to the plug, or welding an old spanner to the plug. But, being this car, I was a bit worried about plugging into it that way. But what the hell, it has almost 160k on the clock. Might as well quit worrying about it.

 

Sounds like your threads are welded man. Happens if you impact gun it hard enough. The flats would work if you can make that happen...maybe


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Not many options left. What are the thoughts of using a pipe wrench? They are designed to grip round pipe. Be prepared to add an extension for more leverage. A pipe wrench may round the plug even further. Have help to hold the pipe wrench on the plug while loosening.
Then if no go, try cutting flats as suggested.

 

Have a shop with a welder weld a large nut to the remnants of the old plug, and use a good socket and wrench so you don't booger it up like the original head. If its as bad as you say trying to turn it with gripping wrenches isn't going to do anything but whittle it down further.

That's a much better solution than taking the whole pan off for a tight drain plug IMHO.

 

I'd say pull the pan. With 160k on it a good cleaning couldn't hurt. You could check the flame trap return while you're in there.