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Old 09-02-2015, 03:27 PM
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Oil drain bolt frozen in oil pan!

Well, I am sure I will post my results, good or bad, after this weekend.

A brief synopsis: bought 2011 Overland from a luxury resale dealer. Love most items on vehicle, others not so much. Went to change oil for first time (EVIC just notified) and the drain bolt is stuck solid to the pan...which is PLASTIC! WTH?

I tried every tool in my arsenal but no go. I took it to a shop I trust (for items I cannot take care of myself = not many BTW) and they tried two different Helix sockets and a 36" cheater bar but stopped with no success as they were worried that they would twist out the cast-in bung. The bolt must have been over tightened, the gasket over compressed so that the inside flange of the bolt head is fused to the pan.

My only two options are to buy replacement parts (pan, gasket, oil pickup tube seal = $300-ish plus a whole lot of disconnect/reconnect underneath vehicle) or drill out the bolt and clean tap the threads ( provided I don't damage them). I also have to figure a clean way to slice the head/washer into four sections and then peen them up and out after collapsing the remaining bolt threads away from the pan insert. It is going to be scary that's for sure.

Going for #2 this weekend so wish me luck as I am going to need it!


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  #2  
Old 09-02-2015, 06:34 PM
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Re: Oil drain bolt frozen in oil pan!

have you tried a good impact wrench on it?

I've had many experiences where a breaker bar would snap a bolt, but an impact would buzz it off with no problem.
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Old 09-02-2015, 08:23 PM
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Re: Oil drain bolt frozen in oil pan!

Head is so screwed up now that either drilling or replacement are only options. Sucks to be me!


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Old 09-02-2015, 10:59 PM
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Oil drain bolt frozen in oil pan!

I think drilling it out might be your last hope. If not, its time for a new pan


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Old 09-02-2015, 11:49 PM
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Re: Oil drain bolt frozen in oil pan!

Sometimes, just a couple for me tho, if you just go one smidge TIGHTER and then immediately reverse it can start it.....at this point with boogered head try large vise grips if trying this option.....good luck man...had the dash/column/hvac out 4 times in my '02 JGC fixing heater cores/blend doors/actuators/evap cores/etc...across 200k and each time I had the feeling you have right now, I'M Screwed! Each time I was only partially screwed and just plowed ahead to brighter days!
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Old 09-03-2015, 09:47 PM
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Re: Oil drain bolt frozen in oil pan!

Spray some PB Blaster on it, let it sit for a bit, then grab the Channel Locks (if the head is already boogered) and get a nice grip on it with them.

As you try turning it, gently tap on the head of the bolt - just don't haul off on it, though. It's similar to a trick I've used for frozen screws - you tap on the end of the screwdriver handle while you try to loosen it with the driver.

Sometimes that jars it loose and lets you wind it out.

The above trick of going tighter, then looser can help, too. A couple of quick jerks back and forth can sometimes break it loose.

It is possible it was cross threaded, which means you're really hurting.

Personally, if you can't get it out, it would be worth the money to not trust a retap and thread and just replace the pan. It's a bolt that's meant to keep the oil in your vehicle. That' not something to take lightly.
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Old 09-04-2015, 05:43 AM
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Re: Oil drain bolt frozen in oil pan!

dunno about the V6, but changing the oil pan on the V8 is apparently a pretty big job.. looks like you gotta drop the engine cradle (I've never done it myself)..
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Old 09-04-2015, 03:24 PM
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Re: Oil drain bolt frozen in oil pan!

Quote:
Originally Posted by quikduk View Post
Head is so screwed up now that either drilling or replacement are only options. Sucks to be me!


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You might want to super glue or weld another screw head to the stripped one and try again. I had some gorilla tighten the head once and I had to use a hammer and the wrench to get it off. Lots of banging involved. Make sure you take that plastic "guard" off (the one with the hole where you change the oil). It makes a huge difference when changing the oil.
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Old 09-04-2015, 06:45 PM
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Re: Oil drain bolt frozen in oil pan!

Weld a nut on top of the bolt, try that first
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Old 09-08-2015, 04:38 PM
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Re: Oil drain bolt frozen in oil pan!

Quote:
Originally Posted by quikduk View Post
Head is so screwed up now that either drilling or replacement are only options. Sucks to be me!


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If you have a Dremel or equivalent, you may be able to machine new gripping surfaces on it. An impact wrench MAY be able to unstick it, but I would expect that the result would be a stripped bolt or threads anyhoo, or it would have come out with a breaker bar.
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Old 10-13-2015, 08:59 PM
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Thumbs up Re: Oil drain bolt frozen in oil pan!

Thanks for all the hints everyone. I wanted to attempt a repair but my family kept "needing" the Jeep...

I finally got the time and decided that drilling was the only way out...literally. I used a good center punch and lined up the center of the bolt head as much as possible since it was now a bit off to one side having had so many tools attempt to remove it from the pan.

I then went at it with a 1/8" TiN coated drill bit until I was approximately 1/4" from the interior end of the bolt. I then followed this with a 1/4" TiN coated bit to the same point. I then packed the flutes with axle grease and proceeded to slowly drill the rest of the bolt through. Best preparations aside, oil got a bit everywhere as it started to drain.

After the oil was out (most of it), I used gradually larger grease filled TiN coated bits slowly until I was just at the "shank" diameter of the drain bolt. I then cut the head off with my air cutoff wheel as well as cut a slot through the remaining head/washer of the bolt until I could just see the red colored o-ring on both sides/cuts. I then used a long punch and began drifting the bolt out via forced rotation.

I lucked out in that it eventually spun out as well as that I was slightly off center when I drilled the bolt, however I never touched the brass threads of the captured pan bung so all was good.

I finished off with liberal use of an articulating magnet to fish out the bits/shavings that escaped my greased drills, then flushed the pan as much as possible with two quarts of ATF (wrong type for JGC) and one quart of 30wt oil I had sitting around. One new drain bolt, oil filter and 8-ish quarts of oil and I was good to go.

Total time, including "fermented refreshment" during breaks and to celebrate my success (and incredible luck)was 7 hours.

At least it saved me around $400 in parts and 15-20 hours to replace the pan.
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Old 11-28-2015, 10:41 AM
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Re: Oil drain bolt frozen in oil pan!

If you had a 2015 with the V6 I would of just replaced the lower pan. Comes with a new drain plug and gasket. That's all you would need and 1hr of your time. I'd feel better about a new pan..

Sorry I re-read your post and see you had a 2011. You did the best option without pulling the motor or 15+ hours of work..


James
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