[SEL] Honda oil plug OT

[Germoamer at aol.com]

Here is a question for all you automotive mechanics out there.

I own a 1993 Honda Accord we bought new, now has 160,000 miles, been serviced 
only by the local Honda dealer with approximately 4000 miles between oil 
changes.  So, that is 40 times the oil plug has been screwed in and out.  We now 
use the car as a spare and only drive once in a while.

About a year ago, the Honda dealer changed the oil and informed my wife she 
had to get a new oil pan as the oil plug threaded hole was worn out.  They said 
they once before had to go to an oversize plug as the thread had previously 
worn and now since it was worn again the only recourse was to put a new oil pan 
on.  They went on to tell my wife this was a common thing to occur and they 
would not guarantee the bolt to not leak oil without the new oil pan.  

So a year has gone by and I finally decided to pull the plug myself and see 
what was what.  The first thing I found was the bolt had been cross threaded at 
some point messing both the bolt and pan threads.  It was cross threaded so 
bad at some time that the pan was not level across the hole, but rather pulled 
out on one side.  To correct the situation, I hammered the pan flat at the 
bolt hole and filed it a little to smooth it, went to the local Carquest parts 
house and bought an oversize bolt especially for a Honda and everything is now 
lovely!

  In my sixty-one years I have never heard of anyone wearing out an oil pan 
hole except from over tightening and stretching things or from cross threading. 
 Remember, this bolt has only been removed and reinstalled about 40 times. I 
believe the Honda dealer screwed up and then wanted us to pay for their 
mistake. 

Would anyone know about the wearing of oil plug holes in Honda's?  The bolt I 
took out is approximately 9/16 thread diameter.  Would anyone know if this is 
the original size?  We intend to have a frank discussion with the Honda 
dealer as we have bought a number of cars from them, owning two now, and had a lot 
of service done there.

Thoughts anyone?

Thanks, 

Tom Schmutz
Concord, Va. USA
Germoamer at aol.com