Stripped fuel drain plug

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Dec 31, 2009 | 06:44 PM

High Binder

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Stripped fuel drain plug

So I went to change the fuel filters on my new (to me) '04 F-350 crew cab the other day. I bought that cool little plug that can be taken in and out just with your fingers that I was going to replace the OEM plug with but when I got under it I found that some

had rounded out the 6mm hole already. I tried to get it out with some other tools, to no avail. Anyway, I'm wondering what it's going to take to remove that plate that the plug resides in so I can remove the bad plug? And how do I get the fuel lines off where they join the plate?

Thanks in advance!

Dec 31, 2009 | 07:26 PM

william_04_x

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You'll need a set of disconnect tools to get the lines off of the HFCM cover.. IIRC it's 5/16 for the return lines and 3/8 for the supply lines..Loosen the filter cover and drain the HFCM before you disconnect anything..

If it were me, i'd take the entire HFCM off of the frame rail and try to get the stripped plug out at the workbench.. Once the lines are disconnected, it's a couple of electrical connectors and 3 nuts to remove it completely..I wouldn't take the cover off, if I didn't have to..

Guys have tried JB welding an allen wrench into the stripped hole and have removed it.. Cutting a slot in the plug and using a big screwdriver has been tried also.

Dec 31, 2009 | 09:07 PM

cheezit

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From: N. Fort Worth, tx

taking the cover off is no big deal. But I perfer to do it on the bench when I take them apart it makes it easer to clean and I get less fuel in my arm pit

Jan 1, 2010 | 09:43 AM

69cj

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From: Middle Tn.

You could also drill a hole in the plug and use an easy out. Think I would try the allen wrench and JB weld 1st. That stuff is pretty strong.

Jan 1, 2010 | 11:21 AM

dschuffert

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From: Illinois

When I stripped mine, I used the screw-out power extractor from Sears: http://www.sears.com/shc/s/p_10153_1...2157000P?mv=rr

Any parts store sells similar. I can't remember which size I used. I took one slightly larger than the stripped hole, lightly tapped it in the hole, and then manually screwed it out. The set listed is designed for power extraction, but I think that would fail in this application, you have to slowly extract it and be able to feel whether it is biting or not. It worked great for me.

Jan 1, 2010 | 07:22 PM

sandmanf250

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if it 's a 4x4 drop front drive shaft take the housing off the frame and take it to the bench and try a small chizel to break it loose it worked pretty slick for me. then take off the manifold and clean the wif contacts,dab alittle dielectric grease in ther and install the new knurled brass drainplug. reinstall and happy motoring.

Jan 7, 2010 | 11:59 AM

High Binder

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That's all awesome info guys, thanks! I'll try the JB weld then the sears easy out thingie and if that bombs I'll just pull the whole thing and fix it proper.

Thanks!