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I drained the oil on my 89 convertible. 2nd oil change since I got her. Put the bolt back in and just kept turning and turning and turning. How bad is it to pull the oil pan in the car? I figure I'll redo the oil cooler lines too. They're all covered in oil and sludge.
If it is just the bolt that is stripped, then you might be ok with just a new bolt.
If it is the nut welded into the pan, you might be able to use an oversize plug at least temporarily.
They sell them at most auto parts stores and they are designed for cutting new threads into a stripped out pan nut. They are a little bit oversize from the standard size.
Bolt is good. I don't want to risk tapping a bigger hole with the pan on the car, but that is the plan once its off. At least I can seal up the drips. I was tempted to use this as an excuse to rebuild, but I don't feel like spending 2-3k right now on a perfectly good engine that just passed CA smog.
Personally I would not be concerned about tapping a new drain bolt for the oil pan. The oil pickup tube has a screen, and the oil is pumped through the filter before distributing around the engine anyway. Yes the filter might bypass but still I would not worry about any shavings, just use a magnet to pull them out if you want to. Unless you are just in the mood to pull the pan.
Something I did a while back to help out a friend. He got an oversize plug somewhere (I suspect from a different mfg engine) and found a tap that matched the threads. Took the tap and soaked it a while IIRC in mineral spirits to clean it off well. Took a rare earth magnet and using some hot glue on the sides stuck it to the end of the tap. Put some grease in the gullets of the tap to pick up any metal cut off and had at it.
Far as we could tell, got it all between the grease and anything left over was picked up by the magnet. I know about 5 years later he was still running the same engine without a problem.
Since the pan, oil cooler and rear seal are all leaky I'd rather pull the pan, unless pulling the pan is impossible while in the car.
Thanks for the replies.
I already have the oil pan out. I'm not just going to fix the bolt and slap it back in. I'm going to clean, media blast, replace or paint everything I can under there. Valve covers too.