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Old 03-06-16, 12:04 PM   #1
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Default Stuck Sump plug

Hi peops - first post here. Looking for some help please

I recently purchased a 2005 SW HDi 2 litre 136 series 1 estate - looks a nice motor, but I'm beginning to have my doubts. I have had Volvos in the past, 8 of them, and have always done my own servicing which has been relatively easy - enough room in the engine compartment to climb in LOL, but the later models I wasn't too keen on.

Anyway, back to the 307. - I just got a warning for low oil pressure which gave me a fright, as car had been running nicely. I decided first job was oil & filter change see if that made a difference. I had a terrible job removing the filter cover - talk about inaccessible, and the hex nut on the plastic cap appeared to be cracked so had to treat it very gently, finally managing to get it undone after buying another strap-type remover - the belt type one I had wouldn't grip.
Move to underneath the car to remove sump plug, to find that that too is damaged, and my 8mm key (good one) is slipping.
I think whoever serviced the car before is an over-tightener
I've given it a good tap with a copper mallet, but no joy.
Does anybody have any suggestions please?
TIA Rob
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Old 03-06-16, 03:11 PM   #2
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Have you tried a socket on the outside of the plug to see if that will shift it?
Failing that find a spline tool that will hammer into the 8mm square drive and some swan necks on the outside if the flats are gone on the nut. After that you'll probably need to weld a new nut to it to move it. It sounds like there's a new one needed anyway.
The filter housing is normally good to undo with a socket. I think it's around 20mm
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Old 03-06-16, 04:27 PM   #3
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I found the strap type oil filter invaluable on the 136 hdi..as much for the fuel filter housing as oil filter. There's just no space to work and plastic fixings just don't inspire confidence
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Old 03-06-16, 08:41 PM   #4
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I have never removed a sump plug for some ten years, I always use a Pela 600 oil extractor. a useless bit of information is that the Mercedes Smart car does not have a sump plug therefor an oil extractor is a necessity.
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Old 03-06-16, 09:10 PM   #5
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Quote:
Originally Posted by smeacat View Post
Have you tried a socket on the outside of the plug to see if that will shift it?
Failing that find a spline tool that will hammer into the 8mm square drive and some swan necks on the outside if the flats are gone on the nut. After that you'll probably need to weld a new nut to it to move it. It sounds like there's a new one needed anyway.
The filter housing is normally good to undo with a socket. I think it's around 20mm
Hi, and thanks for your response - Sadly there are no flats on the outside of the plug - bad design - and the socket is an inadequate 8 mm hex. I'll have a look at a spline tool. Cheers
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Old 03-06-16, 09:23 PM   #6
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It may be completely different from mine but are you sure it's an 8mm hex. Both pugs I've had its been an 8mm square drive.
Of course I don't have your car!.
Sucking it out sounds a sensible option though but I'm old school and like to remove it from below!
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Old 04-06-16, 09:41 AM   #7
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Maybe get a decent pair of molegrips on the outside of plug
or one of those universal wrench's that grip tighter the more force you apply.
just a thought

Last edited by crad20; 04-06-16 at 09:43 AM.
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Old 04-06-16, 10:01 AM   #8
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Last resort why not remove sump
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Old 04-06-16, 10:33 AM   #9
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Snap - on easyout that fits the hole? Maybe with an impact driver to shock it as long as it doesn't damage the sump, are they cast and structural on these?
Too much crushing force from mullgrips will distort the plug but would help with a tight fitting drive inside the plug.
If it ends up as the sump removal is it structural? If so the gearbox needs removal to do it.
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Old 05-06-16, 06:38 AM   #10
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Quote:
Originally Posted by crad20 View Post
Maybe get a decent pair of molegrips on the outside of plug
or one of those universal wrench's that grip tighter the more force you apply.
just a thought


The plug is round with a flat flange which is recessed into the sump so no room for molegrips/stilsons etc. It has resisted a hammer and chisel, I don't have welding skills or facilities, so I'm going down the road of leaving it in until the car is somewhere where it can be dealt with effectively, and in the meantime using an oil suction pump.

Thank you all for your ideas and contributions.
Cheers
Rob
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