Fuel filter water drain plug allen key stripped. Help! - Diesel Forum - TheDieselStop.com
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6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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Old 08-28-2006, 06:43 AM   #1 (permalink)
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Fuel filter water drain plug allen key stripped. Help!

The "water in fuel" light came on this weekend. I got under the truck to open the drain on the fuel filter only do discover that the allen key hole in the plug is stripped and now I can't get the plug out. I bought the truck in December (used) and never had the plug out.

Anyone have any ideas how to get the plug out without removing the entire filter system from under the truck?

Thanks,
Dave
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Old 08-28-2006, 07:58 AM   #2 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

You can try and drive a flat blade screw driver in there to get enough grip, or try and turn it out by tapping with a hammer and chisel. Next steps would be to drill and use an extractor.

I have a new plug sitting in my toolbox right now from International that is knurled for easier removal. It is going in my next oil change. They say it helps in keeping the fuel from going everywhere also when you remove the factory plug.
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Old 08-28-2006, 08:34 AM   #3 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

I think Craftsman(Sears) sells a tool to remove stripped screws. It might work on the drain plug. When you get it out get the IH drain plug and your future problems are solved.
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Old 08-28-2006, 09:13 AM   #4 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

Thanks all. Where can I find the Int'l drain plug. Any web sites? Anyone have a part #?
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Old 08-28-2006, 09:53 AM   #5 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

Knurled HFCM Plug 2589259C91
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Old 08-28-2006, 09:56 AM   #6 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

[ QUOTE ]
Knurled HFCM Plug 2589259C91

[/ QUOTE ]

Who's part number? Ford or Int'l. Thanks
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Old 08-28-2006, 10:10 AM   #7 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

As it has been posted many times, most Ford Parts departments will say the number is no good, tell them to cross reference the number with the commercial truck division. The first part that the dept ordered for me was an exact duplicate of the OEM poor design, the second part was the new and improved "Get R Done" design.
Cost was around $13 for the latter greater much improved design.
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Old 08-28-2006, 11:20 AM   #8 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

[ QUOTE ]
[ QUOTE ]
Knurled HFCM Plug 2589259C91

[/ QUOTE ]

Who's part number? Ford or Int'l. Thanks

[/ QUOTE ]


I believe that is an IHC part number.
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Old 08-28-2006, 11:24 AM   #9 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

That is correct. I paid ~$14 for mine at the IH dealer.
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Old 08-28-2006, 11:41 AM   #10 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

Clicky
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Old 08-28-2006, 12:04 PM   #11 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

[ QUOTE ]
Clicky

[/ QUOTE ]

Awesome, thanks. Now I just need to get the old one out..... [img]/ubbthreads/images/graemlins/grin.gif[/img]
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Old 08-28-2006, 12:56 PM   #12 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

Dave,

You are probably going to need to drop your front drive shaft to get an easyout or screwdriver in there. If you have a 2wd, you're OK. If the plug is stripped, most just get a new cover or gasket kit, remove the cover plate with the stripped plug. If you've got a new plate, just install it. If you are trying to salvage the old plate, you can now work on it on the bench. Either way, you'll need the new gasket/o-ring.
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Old 08-28-2006, 02:30 PM   #13 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

buy a cheap single allen wrench, use a good two part epoxy to "super glue" it into to stripped out plug, let it dry overnight, re-inforce with tape ect if needed, (after obtaining the new improved drain plug) remove and toss both into the garbage! might try JB weld also!
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Old 08-28-2006, 04:44 PM   #14 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

[ QUOTE ]
buy a cheap single allen wrench, use a good two part epoxy to "super glue" it into to stripped out plug, let it dry overnight, re-inforce with tape ect if needed, (after obtaining the new improved drain plug) remove and toss both into the garbage! might try JB weld also!

[/ QUOTE ]

Heck of an idea! It never ceases to amaze me, the things i pick up here! [img]/ubbthreads/images/graemlins/warmsmile.gif[/img]

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Old 08-28-2006, 09:59 PM   #15 (permalink)
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Re: Fuel filter water drain plug allen key stripped. Help!

if the guy who tried to remove the plug in the first place used the correct metric allen wrench, you wouldn't be going through all this.
why people try force something they are not equiped to do is beyond me...
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