Stripped tranny drain plug
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Tourer
Joined: Mar 2007
Posts: 271
Likes: 13
From: OKC
Stripped tranny drain plug
Okay... first, this is like the 4th time I've changed my tranny fluid so yes, I know which plug to pull and how to put it back in. That said, I cross-threaded it and after chasing the old threads with a tap, there isn't enough left to let the drain plug tighten down to required torque values.
I got recommendations from an indy and a dealer to get an oversized drain plug from an automotive supply place. No luck finding the right one so far.
I used to work on air cooled motors in cars in my earlier days and they made steel inserts to fix this problem, wherein you drilled and tapped the hole to an oversize for the insert and screwed and locked it in, allowing the stock plug to be used. Haven't been able to find such a beast for my HD yet.
Any suggestions?
BTW, 07 Fatboy with 6 speed tranny.
I got recommendations from an indy and a dealer to get an oversized drain plug from an automotive supply place. No luck finding the right one so far.
I used to work on air cooled motors in cars in my earlier days and they made steel inserts to fix this problem, wherein you drilled and tapped the hole to an oversize for the insert and screwed and locked it in, allowing the stock plug to be used. Haven't been able to find such a beast for my HD yet.
Any suggestions?
BTW, 07 Fatboy with 6 speed tranny.
Road Warrior
Joined: Dec 2008
Posts: 1,476
Likes: 23
From: Summit, Mississippi
Unless you want to remove your oil pan, I do not think you need to try and install an insert. I am not sure if there is enough material thickness (boss) in that area to install one anyhow.
Over sized drain plugs are very common and I don't understand why you can't find one. They come in several sizes. The original thread is a 1/2 x 20, but....if you can't find an over sized one...I would just tap it out for a larger bolt (fine thread) and use a felt washer. That is all the over sized plug does anyway...just cuts larger threads in the same pitch. A tap will likely not be that much more/less expensive that a thread insert kit. Or, tap the hole out to a pipe plug (NPT).
If you buggar this thing up bad enough...you may wind up taking the pan off anyway to make sure this gets done right.
Over sized drain plugs are very common and I don't understand why you can't find one. They come in several sizes. The original thread is a 1/2 x 20, but....if you can't find an over sized one...I would just tap it out for a larger bolt (fine thread) and use a felt washer. That is all the over sized plug does anyway...just cuts larger threads in the same pitch. A tap will likely not be that much more/less expensive that a thread insert kit. Or, tap the hole out to a pipe plug (NPT).
If you buggar this thing up bad enough...you may wind up taking the pan off anyway to make sure this gets done right.
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
To help avoid cross threading,turn the bolt,plug,whatever turn ccw first.You should feel it drop in a little.At that point turn cw to install.
Last edited by 1flhtk4me; Aug 6, 2010 at 07:01 PM.
Seasoned HDF Member
Joined: Feb 2007
Posts: 6,072
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From:
Available at pep boys, advance auto parts, napa.
Consider review of link bellow.
http://www.bigboyzheadporting.com/showthread.php?t=85
Consider review of link bellow.
http://www.bigboyzheadporting.com/showthread.php?t=85
Seasoned HDF Member
Joined: Feb 2007
Posts: 6,072
Likes: 1,124
From:
Another alternative:
Look inside the drain hole..sometimes there is A LOT of thread available much higher/deeper.
Might consider using a longer PILOT POINT drain plug in same original factory size.
Options mentioned will not permit use of original factory o-rings but you could use the metal framed rubber washers that are hanging right next to the oil drain plugs.
Look inside the drain hole..sometimes there is A LOT of thread available much higher/deeper.
Might consider using a longer PILOT POINT drain plug in same original factory size.
Options mentioned will not permit use of original factory o-rings but you could use the metal framed rubber washers that are hanging right next to the oil drain plugs.
Seasoned HDF Member
Joined: Feb 2007
Posts: 6,072
Likes: 1,124
From:
Finally i would avoid use of an insert because positioning is difficult on the bike.
The article in link above is correct about the o-ring on the piggy back moving.
The piggy back also has a larger head and sits lower on some bikes which may cause a problem with motorcycle jacks.
The longer bolt would seem the least damaging.
I have worked with the oversized myself.
And as many of us have learned the hard way:
The oil drain plug requires very little torque..A little past finger tight.
The article in link above is correct about the o-ring on the piggy back moving.
The piggy back also has a larger head and sits lower on some bikes which may cause a problem with motorcycle jacks.
The longer bolt would seem the least damaging.
I have worked with the oversized myself.
And as many of us have learned the hard way:
The oil drain plug requires very little torque..A little past finger tight.
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Tourer
Joined: Mar 2007
Posts: 271
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From: OKC
Thanks for the help guys; IM, your link was especially helpful as the differences in drain plugs was something I was unfamiliar with.
My background in mechanics was working on cars, and specifically VWs, a number of years ago and occasionally, the odd bike here and there. I have used both heli-coils and different inserts in an aluminum based material with varying success. For this application, the only insert I would have considered is a hat style where the hat shoulder bottoms against the original surface locking it in. I know there is enough material there for the type I was thinking of to have worked, and considering the 2" wide shocks set below the bolt head, I wasn't worried about dragging it. Helicoils, expecially the non-bottoming kind, never seem to work well in an aluminum type material due to differences in heat expansion properties.
In the intervening time when I wasn't in the business, obviously they have had some technology improvements so seeing the oversize drain plugs referenced definitely tells me where to go with this. I wasn't sure what the single oversize, double oversize, piggy back references meant until I saw the link. I ran a 1/2-20 bottoming tap through it last night, rinsed it through with some clean kerosene, and tried to tighten it up; had the torque wrench set to 60 in/lb and it never got close to clicking before the last remaining thread or two gave way. I'm headed out to find the right oversize plug today.
Thanks all.
My background in mechanics was working on cars, and specifically VWs, a number of years ago and occasionally, the odd bike here and there. I have used both heli-coils and different inserts in an aluminum based material with varying success. For this application, the only insert I would have considered is a hat style where the hat shoulder bottoms against the original surface locking it in. I know there is enough material there for the type I was thinking of to have worked, and considering the 2" wide shocks set below the bolt head, I wasn't worried about dragging it. Helicoils, expecially the non-bottoming kind, never seem to work well in an aluminum type material due to differences in heat expansion properties.
In the intervening time when I wasn't in the business, obviously they have had some technology improvements so seeing the oversize drain plugs referenced definitely tells me where to go with this. I wasn't sure what the single oversize, double oversize, piggy back references meant until I saw the link. I ran a 1/2-20 bottoming tap through it last night, rinsed it through with some clean kerosene, and tried to tighten it up; had the torque wrench set to 60 in/lb and it never got close to clicking before the last remaining thread or two gave way. I'm headed out to find the right oversize plug today.
Thanks all.
Last edited by Yosemite; Aug 6, 2010 at 12:30 PM.
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Thread Starter
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Tourer
Joined: Mar 2007
Posts: 271
Likes: 13
From: OKC
I know better... in my current profession, safety rules and there is no such thing as "maybe". I was just stupid the other night and now I'm paying for it.