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Unread 11-07-2019, 07:17 AM   #1
Not Yet Wild
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Default G2 oil change gone wrong - engine coming out

Well, I am a bit embarrassed to say that while performing the second oil change on my new to me G2, I must have over-tightened the oil drain plug and I think I stripped the threads on it. It's embarrassing because I am only a newbie to golf carts, not to turning wrenches. I've owned a few vehicles with aluminum oil pans and never had an issue. I also have a '70 Honda QA50 and Trail 70, both of them I use and maintain and have never over-tightened the oil drain plugs on those.

I think this Saturday bright and early this engine is coming out of the cart so I can properly address a couple of things. I have already replaced the hose that delivers oil to the valve cover, but the whole engine is caked in oil and grime and it smells like hot/burnt oil every time I drive it. So I will pull the engine out and degrease everything, replace any vacuum or oil lines then address the two big issues I have.

1. I guess I will replace the oil plug with a slightly larger self tapping style. Anyone have any thoughts on performing this task? Would I be better off to drill and tap with a proper tap and then just buy a larger oil plug?

2. The oil fill neck - does not stay in, it doesn't just fall out, but wiggles around and you can easily lift it straight out of the motor. I have tried putting an O-ring on it but then it slides in until the o-ring and doesn't go all the way down. I have also tried some high heat / high vibration RTV to see if that would lock it in place, didn't work. A user here CP241 I believe recommended JB welding it in. I bought the JB weld, and while I know CP is 100% correct I just have a hard time wanting to use JB weld. In my mind its like slapping some duct tape on something (no offense CP). If there is in fact a different solution that isn't as permanent as JB weld I'd like to go that route. Anyone who has torn apart a G2/9 engine please let me know how the oil fill neck is secured to the block from the factory?
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Unread 11-08-2019, 08:25 AM   #2
Not Yet Wild
Yamaha
 
Join Date: Oct 2019
Location: Houston, TX
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Default Re: G2 oil change gone wrong - engine coming out

I see a lot of folks have viewed the post, just curious if anyone has ever stripped their oil plug and how they repaired it?

Bueller, Bueller?
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Unread 11-08-2019, 09:12 AM   #3
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Default Re: G2 oil change gone wrong - engine coming out

J-Rob, I can't help with the stripped drain plug. But I just poked at my G9 regarding the Oil Fill, and mine looks to be welded to the case itself. See pics.
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Unread 11-08-2019, 09:24 AM   #4
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Default Re: G2 oil change gone wrong - engine coming out

Its compression fit in there. Theres really nothing behind it, under it, or around it. I'd still use JB weld.

As for the oil plug, I'd first try and tap it with the correct size tap. Just to chase the threads and maybe it will clean back up as long as it's not COMPLETELY stripped and spinning freely in there. Otherwise I've always used a time-sert when j get a stripped out drain plug. It's sort of like a helicoil but permanent.
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Unread 11-08-2019, 09:46 AM   #5
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Default Re: G2 oil change gone wrong - engine coming out

Another option I used was to drill and tap and use a SAE thread oil plug. Makes everything good as new.
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Unread 11-08-2019, 10:00 AM   #6
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Default Re: G2 oil change gone wrong - engine coming out

Quote:
Originally Posted by raydhd View Post
Another option I used was to drill and tap and use a SAE thread oil plug. Makes everything good as new.
Also a good option. The SAE plugs are threaded more coursely than the fine thread metric ones are. lot cheaper than a time-sert too. they're pricey but do work well. Toyota used them on a head gasket recall where the studs were stripping the threads out of the block... they're plenty strong for a drain plug :)
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Unread 11-08-2019, 05:48 PM   #7
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Default Re: G2 oil change gone wrong - engine coming out

I have had to do a few. I drill it out & tap it for a 1/2-20 plug. Dip the drill bit in grease to catch shavings. Also dip the tap in grease for the same reason. Remove the tap several times during the process and clear the shavings. Oh yeah, I almost forgot, a 1/2" drill bit is not the correct size for a hole you want to thread to 1/2", but I cannot remember the size to use (very important).
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Unread 11-08-2019, 08:10 PM   #8
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Default Re: G2 oil change gone wrong - engine coming out

There we go. The whole procedure laid out by a pro
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Unread 11-08-2019, 09:42 PM   #9
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Default Re: G2 oil change gone wrong - engine coming out

You guys are awesome! thanks for the advice! I will try a thread chaser first, if that doesn't work, I will try the 1/2" plug and research what size to drill before tapping.

I'll also buy a couple of quarts of cheap motor oil to pour through it to make sure I capture any shavings that don't get stuck in the grease on the drill bit or tap.

I appreciate all the advice!
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Unread 11-08-2019, 09:48 PM   #10
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Default Re: G2 oil change gone wrong - engine coming out

29/64 drill
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