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While changing the oil today, I felt thru the oil pan to see if there was any sludge on the inside. That is when I felt the bolt. I fished the bolt out and it was a hardened bolt that had broken off with about 1/4" of threads remaining. Pulling the oil pan it looked like an oil pump bolt was missing (the one off to the side and not the two near the gear. Pulling the pump reveals the remainder of the bolt in the block.

Anyone had this happen? I don't know how long its been out, but I've only done one other oil change but don't think I felt inside the pan. The only method I can think of is drilling the bolt and using an EZ-out. Or I if I'm good enough, I could drill the center with progressively larger bits and use a tap to clean the remaining bolt fragments out. Comments?

It is a common failure, usually an easy extraction, use a left hand drill bit and or a scribe. You may have to replace the mating gasket if it is blown out(it is copper)

If this is a common failure, would you recommend replacing the bolts with a higher grade as preventive maintenance?

Jim LaGuardia wrote:It is a common failure, usually an easy extraction, use a left hand drill bit and or a scribe. You may have to replace the mating gasket if it is blown out(it is copper)

Thanks for the feedback. About 60% of the copper gasket was still there. I'll replace it and the main oil pan gasket.

Use a bolt of the same strenth, it is better to break a bolt than the engine case

Is the one bolt off to the side more prone to breaking or can any of the three let go? Just curious because I'm inclined to replace all three while I'm in there.

The lone bolt is the common failed bolt, I would speculate you need to run a thinner oil in cold weather(10-30) due to your geographic location.

That is the weight I use. I'm guessing that it broke before I got it.

OK I have a question on using a drill. The bolt hole is real close to the skirt of the block, so I'd think you'd have to use a real small drill (1/4" mini drill?) or a bit extension. I don't think anything I have will get in there and drill straight.

Use a spring loaded centering punch and a scribe first, it may come out very easy as the ones I have done.

Jim you are The Man! The remainder of the bolt came out with just a little effort. Used the spring loaded center punch in a couple of spots off center, then an awl with an 8 oz. ball peen. Once flush with block, you can use your thumb to turn it out.

Jim there is a steak dinner with your name on it if you ever get out this way. Thanks for your help.