[Chuck34]

I recently changed the oil in my 08 420 rancher, while putting the plug back in with a torque wrench the threads on the inside broke. Any advice on a fix that doesn't require replacing the caseing. I've changed the oil in this machine at least 15 times and never had this problem.

 

[retro]

There is a piece of the crankcase casting that breaks off when the oil plug is overtightened. The cases will need to be split and the broken case replaced.

Welcome to the forums!

 

[JohnnySolo]

Couldn't one use a Tap-n-dye set and make new grooves?

 

[Carolynskii]

No you cant tap it the engine wall is too thin. The piece that broke off is the raised piece that the screw goes into and it's not there anymore or pieces missing.
You gotta split the case and the pieces out or it will absolutely tear up your engine.
Afterwards You could get a rubber oil plug from autozone but sometimes they leak a little.

 

[billy5221]

I had the same thing happen to my 08 shortly after I bought it new. Now I know people say it's from over tighten it, maybe that's case for some people but IMO it is just a very bad design. I know how to change oil been doing it my whole life and I know I did not over tighten, barely got it snug and it snapped off. I got the piece out of there by just pulling the top end and fishing around in there, I did pull the motor though so I could shake it around.

 

[Wsg]

I recently changed the oil in my 08 420 rancher, while putting the plug back in with a torque wrench the threads on the inside broke. Any advice on a fix that doesn't require replacing the caseing. I've changed the oil in this machine at least 15 times and never had this problem.

I have never had the need but have heard of using a rubber boat plug as a stopper.


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[alloutdoors]

I think the best opinion is to split it and address it correctly, because a short cut and then starting the engine could be catastrophic if something is left in and breaks loose or if the repair put metal shaving in the block or if a patch fails losing all the oil while riding. No question, this will be a major task, but consider it an opportunity to clean and replace items along with way while inside...

 

[Wsg]

I think the best opinion is to split it and address it correctly, because a short cut and then starting the engine could be catastrophic if something is left in and breaks loose or if the repair put metal shaving in the block or if a patch fails losing all the oil while riding. No question, this will be a major task, but consider it an opportunity to clean and replace items along with way while inside...

I do agree with fixing it right but as a temp fix while locating parts. I use my atv to plow the driveway I wouldn't go trail riding unless I felt like a long walk back if it came loose.


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[SamUK]

This is one reason you should always run an engine for 10-15 minutes before draining oil, everything expands especially the alloy casing. Usually makes for a better release of fasteners, in this case, the drain plug. I always apply a small amount of copper grease to my drain plug, it never gets stuck or sticky in the threads. I also never torque it up, hand tight plus a ‘little bit’ is more than enough.

In your case as has already been said, there really isn’t much you can do other than split the cases or buy a replacement motor and swap them over.

 

[JohnnySolo]

No you cant tap it the engine wall is too thin. The piece that broke off is the raised piece that the screw goes into and it's not there anymore or pieces missing.
You gotta split the case and the pieces out or it will absolutely tear up your engine.
Afterwards You could get a rubber oil plug from autozone but sometimes they leak a little.

That makes sense. Silly me