Went to change the oil in my '96. Tightened plug to 40 ft lbs. Leaking. Went to tighten to 60 ft lbs. Never got there. Plug flange snapped off. Got new (stock) plug. Cleaned area really well. Installed with new gasket to 40 ft lbs. STILL LEAKING! Tightened to 60 ft lbs. STILL LEAKING! Went a little beyond 60 ft lbs (I know, I shouldn't have). New plug flange pops off. Go get yet another stock plug, put on new gasket/washer thingy, install o-ring between gasket and pan, put rtv between plug and gasket and between gasket and pan, check oil pan for cracks or irregularities, let rtv dry overnight, fill with oil and now, although not nearly as much as before, IT'S STILL LEAKING! This is driving me nuts!!! I'm no nimrod when it comes to things mechanical. I've been an aircraft mechanic for 21 years, so you'd think I could put a stinkin" oil drain plug in without messing it up. Any help would be greatly appreciated. Sorry for the rant.

 

The thread portion of the drain plug in the pan must have let go or something.

I know what you mean, its not that complicated set up for sure. You need to clean it with some brake cleaner around the drain hole and have a REALLY good look at it.

I hope you get it sorted out.

Jason

 

40 ft/lbs is way more than is necessary even though the manual calls for it. More than likely the oil pan is now distorted. Some folks have been able to flatten the sealing area back up with a sanding block.
Another fix is to install a drain valve type plug with a thick gasket and silicone and never remove it again.

 

Crap!!! I searched by favorites over and over and thought I saved a link to some aftermarker drain plugs specificly for our Cummins to elimanate any leaking/problems. I'll keep looking.

 

this is the one i got to fix that proplem seams to be working good
hope this helps
jman


http://www.turbodieselregister.com/c...uery=retrieval

 

This may help, they have the thick nylon washers. I have had good luck with them. They even have the magnetic drain plugs at a nice price. Heres the link:

http://cgenterprises.com/

I also bought the drain valve thingy from Genos. Nice quality, but I have a 2 wd truck. Guess whats the lowest thing on the bottom of the truck? Totally exposed, no protection. Was worried about getting that thing hit. So went the the nylon washer and all is well. Good luck, Kevin