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[Agemo]

As title, took out the sump plug, felt OK (if a little tight for the first few turns) When I screwed it back in, it felt OK, never even got a socket on it, it just started to go finger-tight,  then went a bit more, then finger-tight again.  Was turning forever, no warning at all. I changed the oil myself last time & everything went fine, although I think I used a torque wrench to nip it up (for the first time ever!). I have looked at the plug, which looks a little worn, so I am assuming it's the sump insert that has the weakest threads.

I suppose my options are:-

1/ Helicoil, - no experience of these, plus I haven't any taps etc.

2/ Change sump for a new/second hand one, - I quite like this idea, I would know the inside of my sump wasn't an inch thick with sludge
.
3/ Bigger sump plug, - Is it possible to just replace the plug, with something "one size bigger?"

I would like to know if there are any other options, and I may be after a replacement TD sump.

[Seth]

Experienced the exact same occurrence on mine Glen
I found that the cast boss was actually split - not the threads being stripped.

There's no threaded insert in the sump, so examine the 'boss' carefully.
If it's okay, simply heli-coil it and keep your fingers crossed.
 

If you're looking at changing the sump, (as I had to), you'll need to remove the sub-frame, after supporting the lump, which is not an easy task.
You should also, ideally, have a full geometry set-up/check - unless you can replicate the sub-frame's exact location.
 

Hope the heli-coil route works for you mate, and I now use a syphon-type extractor thingy!
 

[Agemo]

OK mate, thanks for that. I will nip out and inspect the boss. Didn't realise a sump swap was such a pain!  :-/

[Agemo]

OK, had a look, the boss looks fine. I think it's Helicoil time, will have to wait for someone to give me a lift to Halfrauds or somewhere.
The plug doesn't look bad, perhaps not perfect but usable, although I may as well get another.

I know, crap picture, but they do show the thread isn't that bad.  I didn't realise the was no insert, just a threaded hole in a bit of Ally!

[Shackeng]

Had the same problem, drilled it with a 12mm drill, and fitted an M14 x 1.5 plug. That was about 6 oil changes ago, no further problems, but I pump out now anyway, so no need to remove the plug. Incidentally I used a 12mm drill rather than the recommended 12.5mm for this size plug, (then tapped it) and it was the ideal size in ally, probably 12.5mm would be OK in steel.


HTH 

Edit: Forgot to say I tapped it to the above size.

[Marks DTM Calib]

12.5mm will be fine in alloy to as when you use a 12mm the tap just removes the extra 0.5mm.

I  ave used a spark plug helicoil (as its a more useful kit to have!) and a peugeot sump plug (pretty sure its a pug one)

[Shackeng]

12.5mm will be fine in alloy to as when you use a 12mm the tap just removes the extra 0.5mm.

I  ave used a spark plug helicoil (as its a more useful kit to have!) and a peugeot sump plug (pretty sure its a pug one)

Agreed.

[Agemo]

OK now I have seen the job, I don't fancy changing sumps!  It looks worse than I thought, not sure about how to go about it yet, but if there is no option . . .
Helicoil, again I am not happy with the sounds of this, doing the job in situ, swarf in the sump, never even seen a Helicoil kit. I would need a bit of advice. Hmmm . . .
I do like the idea of getting the sump off, nice to know the inside is clean, but what a job!

[Agemo]

STOP PRESS. I noticed that the thread is an M12 x 1.5, which is the same a wheel stud. I tried a brand new stud, and although I haven't had a spanner in, I think it is a decent fit (not perfect but better). The sump plug feels more of a round thread than the Vee thread on the wheel stud. This gives me some breathing space, I could fit it the wheel stud with Loctite, so I have transport. I can then acquire a new sump, or get a Helicoil kit, or a replacement sump, and do the job at my leisure. 
Another option is to get a sump plug one size bigger, or would this be too big? Any thoughts on this gents?

[Shackeng]

STOP PRESS. I noticed that the thread is an M12 x 1.5, which is the same a wheel stud. I tried a brand new stud, and although I haven't had a spanner in, I think it is a decent fit (not perfect but better). The sump plug feels more of a round thread than the Vee thread on the wheel stud. This gives me some breathing space, I could fit it the wheel stud with Loctite, so I have transport. I can then acquire a new sump, or get a Helicoil kit, or a replacement sump, and do the job at my leisure. 
Another option is to get a sump plug one size bigger, or would this be too big? Any thoughts on this gents?

See my post above ref drilling and tapping, took very little time and fixed it.

[Agemo]

Thanks Shack, yes I read that, just that I have not used one so am a little apprehensive. I will see what I can buy tomorrow, hopefully a tap, Helicoil, and bigger sump plug.
It's a shame nobody markets a tapered plug, sounds ideal for a lot of people. Why are they all parallel threads?

[Marks DTM Calib]

Because a tapered plug on alloy would be even more likely to strip threads.

Do remember that with a Helicoil you dont need a larger size sump plug and you do get a much stronger thread

[Agemo]

Right, fair comment.  Oh! I didn't realise that, good point. I like to keep things standard. Thanks.

[Seth]

OK now I have seen the job, I don't fancy changing sumps!  It looks worse than I thought, not sure about how to go about it yet, but if there is no option . . .
Helicoil, again I am not happy with the sounds of this, doing the job in situ, swarf in the sump, never even seen a Helicoil kit. I would need a bit of advice. Hmmm . . .
I do like the idea of getting the sump off, nice to know the inside is clean, but what a job!

I also used a 12mm drill (before realising the actual casting was split!), and found it really straightforward Glen.
Just drill gently and slowly, and in a few seconds you're done.
Swarf will tend to emerge downwards along the drill-bit flutes anyway - so don't worry over it!

[Agemo]

Yes thanks, I have had a think & decided Helicoil is my best option. I can run a pint or two of oil through the plug hole, and as you said, most tends to go away from the direction of drilling. I will put the car back on the road and go Helicoil shopping.
   Thanks for the help.