XJ6 & XJ12 Series I, II & III 1968-1992

XJ6 Sump Plug Repair?

 
  #1  
Old 02-17-2019, 01:30 AM
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Default XJ6 Sump Plug Repair?

Good Evening All,

I'm getting very close to getting my XJ6 back on the road and as such I've giving everything the once over. First problem found! I have oil leaking from the sump plug. I've removed the plug and it looks like the sump has had a previous helicoil repair? I'm assuming that they weren't helicoiled from the factory?

What are my option for repair? I have found something for AJ6 engines, but not the XK?

Woz
 
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Old 02-17-2019, 02:06 AM
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I went to the local parts store, happened to be my place of employment at the time, and found a 14mm sump plug, Mitsi/Toyota/dunno, and then snooped around some more, and found a 14mm Taper tap, and drilled the sump to the size for the tap spec, and that I forget now, but since I was using a 1st taper thread tap it was only a "lick", and rethreaded that alloy sump to take the 14mm sump plug, simple.

THEN

Dont let idiots change your oil.

NO, they were not helicoiled from the factory, and usually oil will seep between the coil and the parent, and ya got a leak.
 
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Old 02-17-2019, 02:27 AM
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Thanks Grant,

I've taken a closer look now and I can clearly see the helicoil (of the wrong depth!) but, the sump plug thread is 5/8-18 UNF (15.875mm x 1.41mm), so an M14 won't be enough. I'll need to find the helicoil thread size and maybe make an adapter or just go up to 3/4 UNF and use a new sump plug?
 
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Old 02-17-2019, 04:10 AM
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Commodore V6, say VXish has a 19mm threaded sump plug, memory here, as I am not at work at the moment. They do have a standard 14mm plug and then this option for the bigger one. My sons V6 S/charged has the big plug as supplied by GM, so not molested.

Duck into Super Cheap, they should have a chart for all cars, Kelpro is one brand, and pick one that suits, and then a tap, and done and dusted.

Late S3, and AJ6/16 has a "monster" thread sump plug, but I reckon that is going too far, or maybe not.
 

Last edited by Grant Francis; 02-17-2019 at 04:23 AM.
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Old 02-17-2019, 05:14 AM
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Well the drill size for the current helicoil is 41/64" (16.27mm), so you need to go to 3/4-16 to remove the helicoil thread. The 3/4-16 needs a 17.5 hole to tap into.

Although, being Aus it will be easier (cheaper) to go with a metric thread. M20x1.0 would do the trick. I'll have a shop around tomorrow.
 
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Old 02-17-2019, 05:23 AM
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Here’s a pic of the current situation!



You can clearly see the helicoil has partially wound out and it is some way short of full depth.
 
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Old 02-17-2019, 06:21 AM
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OOPS.

Very sloppy repair by any standards.

Maybe, unwinding it carefully, cleaning with Solvent (Carby cleaner etc) and loctite the coil into place. Then a decent copper washer, or a Dowty washer, nd should be fine.

The depth is no matter, just the security and the face finish is what gives the seal.
 
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Old 02-17-2019, 01:35 PM
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Remove the loose Helicoil. Use a new one with tools. Seat the new coil. Use a better washer under the bolt.

J-L has a long thread on the issue..

Carl
 
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Old 02-17-2019, 07:19 PM
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Yep, thanks gents. That is the current plan as it will be the quickest as long as I can get the insert and I have the correct make. From experience different manufactures use different insert threads. 'Champion' inserts for example are not compatible with 'Recoil'.
 
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Old 02-17-2019, 11:34 PM
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The fun never ends here! I pulled the old helicoil out and half the thread came out with it. I pulled on the tang gently but, it was super brittle!

looks like I will be up sizing!



Woz
 
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Old 02-18-2019, 02:08 AM
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BUGGA.
 
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Old 02-18-2019, 10:33 AM
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YUK!!!

Who ever "installed" that Helicoil made mess. As I get it,. once the coil is seated in the new clean threads, the tang is to be busted off, It's location job done.

It looks like there is enough "meat" left for a new bore and a clean tap. And, yeah, the threads are straight and as sucj do not seal, they merely fasten. use a good washer and all should be well....

Carl
 
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Old 02-18-2019, 12:42 PM
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We did repair on my buddies BMW aluminum oil pan drain screw by simply drilling and tapping one size bigger hole. I think we went from 17mm head bolt to 19 mm bolt (probably M12 to M14 thread size). Maybe similar repair could be applied here?
 
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Old 02-18-2019, 03:49 PM
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Easy enough job with the correct tools, I had to increase my S11 sump plug and went to the local hydraulic hose repair place that I was friendly with during my wrenching days, they had a plug that could be used and loaned me the correct tap to use.
maybe an option for the OP?
 
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Old 02-19-2019, 02:17 PM
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Job done! Hole drilled out to 17.5mm and tapped to 3/4-16 UNF. Just need the correct size crush washer now. I used a Dremal to gently chamfer the outside of the hole as a chunk had come off around one half. Then used the drill taking care to align it perpendicular to the face.

The hardest part was removing the swarf from the sump! The larger hole allowed me use my little finger to get most of it. I then threw some fresh oil into the top of the engine to flush it out.
 
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