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I am having trouble with the oil pan plug leaking. It has been in the shop 4 times and they have replaced the plug twice and the gasket twice and it still leaks. Does anyone have any suggestions other that replacing the oil pan.
 

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I would really encourage you to find the actual problem. There is nothing special about a drain plug... a new one, properly installed, won't leak. If there are still leaks from that area, it means something is damaged. A cracked pan, stripped threads, leaky oil pan seal, etc. IMHO it would really be worth your while to find out what it is. Somewhat related, I would be really suspicious of a shop that thinks multiple drain plug replacement is gonna fix anything. To me, that seems a bit amateurish.
 

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dcfrisbie
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Discussion Starter • #1 4 hours ago
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I am having trouble with the oil pan plug leaking. It has been in the shop 4 times and they have replaced the plug twice and the gasket twice and it still leaks. Does anyone have any suggestions other that replacing the oil pan.


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Like jvanabra said, it's not the plug.
Somewhere above the plug is leaking and the drips are collecting at the lowest point - the drain plug, before dropping off.

You need to do a serious degrease then check for leaks on the clean, dry engine.
I hope it's not the rear main seal but if it is, Lucas Main Seal Stop Leak works well.
There's no substitute for replacing the seal though.
 

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Typically local Schwarzenegger tightened oil drain plug with 3m bar extender. Oil pan cracked.
 

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TBH that's my guess as well. Radial cracks in the drain plug hole. If I was a betting man, I would bet the shop that thinks replacing the plug multiple times will fix a leak is the same shop that strong-armed the plug in the first place. I've ended up with multiple cars (Volvo, Chrysler, Audi, Saab) where that's happened.

I will mention that I recently fixed a friend's Ford Fiesta, where the source of the leak was actually a tiny crack near the drain plug that was probably caused by bottoming out... it gave every appearance of a drain plug leak but after I cleaned it up thoroughly the source was clear. The good news for her was that replacing the pan cost $62 and maybe 90 minutes of my time.

The Saab is a bit more complicated, though thankfully not obscenely so. Fixing that Audi... oof. What a pain.
 
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