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Old 07-26-2021, 11:21 PM   #1
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THOR #24324
Onan 4000 Oil drain cover issue

I recently purchased a used 2018 Thor A.C.E 30.4, and we've been really pleased with it. However, I am having an issue with changing the oil on the Onan 4K. The green cover under the oil drain plug.... Both the Torx screws are stripped and rounded, and I don't have a conventional method to remove them.... that I'm aware of. It was like this evidently before I took ownership, I'm suspecting an impact was used. So, questions:

1) What can I do to safely remove the Torx screws?

2) Once it's removed is it even necessary? I suspect it is due to the proximity of the tire to the generator.

PS - Duct tape isnt a qualifying answer: lol:

Thanks!

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Old 07-27-2021, 12:07 AM   #2
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Several ways to get them out.

Here are a couple that are cheap and easy
https://www.amazon.com/VISE-GRIP-Ori...7343516&sr=8-5
Then
A screw extractor
https://www.amazon.com/Extractor-Str...45619381&psc=1

These are available at auto supply and hardware stores.

YouTube will show you how to use them.


https://www.youtube.com/results?sear...tor+how+to+use
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Old 07-27-2021, 12:12 AM   #3
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I have used the screw extractor before on a damaged screw on a disc brake rotor to remove the screw. It worked great.


Paul
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Old 07-27-2021, 12:25 AM   #4
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Thank you! This is something I've not had much experience with, or it was a situation where I would drill it out and go on. In this case, I didn't want to risk hitting anything else. I just ordered the tools, now i need to find replacement bolts...thanks again!
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Old 07-27-2021, 12:26 AM   #5
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THOR #13058
If we can't recommend to use Duct tape, then you must supply a picture. I just had a similar issue with a recessed allen screw on a faucet fixture that was rounded I saturated with Penetrating Blaster and took the ball side of allen wrench tool and pushing on one end a time, 10 minutes later it was free and took forever but I got it out. Put it right into the trash can.

I don't know what it looks like but I have used vise grips to get off stripped oil plugs. It is invaluable tool.
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Old 07-27-2021, 01:26 AM   #6
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If there is enough head to the screw, take a dremel type tool or a thin circular cutoff wheel and cut the head to make it a slotted screw, flat tip. Short of that, drill the head off.
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Old 07-27-2021, 02:31 AM   #7
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If you have a wide assortment of flat-head screwdrivers or bits, chances are one will snug down into Torx pattern tight enough. I suggest soaking the screws with penetrating oil (PB Blaster or similar) and let it sit for maybe an hour or so before trying. Old school... I've removed many a boogered up screw that way.
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Old 07-27-2021, 02:57 AM   #8
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Cut it off and use Gorilla Tape to cover the hole.

Hey, he said no Duct Tape,
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Old 07-27-2021, 03:07 AM   #9
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Originally Posted by chunker21 View Post
If there is enough head to the screw, take a dremel type tool or a thin circular cutoff wheel and cut the head to make it a slotted screw, flat tip. Short of that, drill the head off.
How I would approach this situation as well
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Old 07-27-2021, 11:47 PM   #10
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Thanks everyone, the duct tape was a joke coming from another friend as a solution. I've got some screw extractors on order, will hopefully test it out this weekend, if not itll be the Dremel route.
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Old 07-28-2021, 12:52 AM   #11
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Originally Posted by daveflowers1 View Post
Thanks everyone, the duct tape was a joke coming from another friend as a solution. I've got some screw extractors on order, will hopefully test it out this weekend, if not itll be the Dremel route.
Very good, and if neither of those solutions work; you can always go back to the Duck tape approach if you get serious for a real fix and stop joking around

Good luck.
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Old 07-28-2021, 02:36 AM   #12
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Whatever "friend" said to use duct tape is an idiot.
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Old 07-29-2021, 05:39 PM   #13
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Is the head buggered or the threads? I donít recall whether is an actual bolt into a secured nut or just a sheet metal screw. If the head is damaged the screw extractor or vice grips should do the trick. They are small and not torqued very much. They lead a hard life though and it certainly couldnít hurt to soak them good with penetrating oil. Incidentally, you really only need to remove one of them and just rotate the cover out of the way to gain access to the drain plug. If itís damaged threads or a stripped nut youíll probably have to drill it out. I donít think there is anything ďaboveĒ that you are likely to damage. If the nut is ruined you probably can reinstall the cover using a speed-nut. I donít think Iíd lose a lot of sleep worrying about operating the generator without the cover if it comes to that.
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Old 07-30-2021, 12:39 AM   #14
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Quote:
Originally Posted by AxialFlux View Post
Whatever "friend" said to use duct tape is an idiot.
The Friend of the Friend that says to use duct tape is your Friend.
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Old 07-31-2021, 11:11 PM   #15
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THOR #21497
Quote:
Originally Posted by daveflowers1 View Post
I recently purchased a used 2018 Thor A.C.E 30.4, and we've been really pleased with it. However, I am having an issue with changing the oil on the Onan 4K. The green cover under the oil drain plug.... Both the Torx screws are stripped and rounded, and I don't have a conventional method to remove them.... that I'm aware of. It was like this evidently before I took ownership, I'm suspecting an impact was used. So, questions:



1) What can I do to safely remove the Torx screws?



2) Once it's removed is it even necessary? I suspect it is due to the proximity of the tire to the generator.



PS - Duct tape isnt a qualifying answer: lol:



Thanks!
Don't run your Onan without the cover. My 5500 was a warning on the outside. Will overheat. My cube pulls off. Had to superglue one post back on as the original owner had as much trouble figuring it out as I did.
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Old 08-02-2021, 11:45 PM   #16
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Left handed drill bit
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