Hot Water Heater Drain Plug

[Wyokirk]

On the road in Northwestern Minnesota. Needed to drain hot water tank today. When I reinstalled the plastic plug, the head broke off, leaving the threaded portion of the plug with about a 1/2 inch hole in the middle - heater won't hold water. Tried to remove with the tools I have - not luck. I don't want to get too aggressive and ruin the threaded portion in the hot water heater.

Also, on our way to Canada to be on the Polar Bear & Northern Lights Caravan - need a solution soon.

Questions:
1. Has anyone had this happen to them and how did you remove the remainder of the plug?
2. If you haven't had this occur, any ideas on removal?
3. Any RV repair location in this area (Northern Minnesota or Southern Manitoba you would recommend?

Thanks in advance for replies

[jmickow]

Assuming that the head twisted off and left just the outer threaded portion of the pipe with a hole in the middle, the best approach is to use a pipe nipple extractor, like these:

https://www.homedepot.com/p/Husky-Pi...0&gclsrc=3p.ds

You might also be able to find something similar like an Easy-Out set someplace like Harbor Freight for not too much money, or even a t-handle pipe reamer if the diameter is proper. Anything to slip into the hole and grab the inside of the fitting so you can turn it out. Maybe even one of those step drills would work, but make sure to turn in reverse with a wrench on the hex shaft, not a drill, to avoid damaging the fitting.

Easy to find Camco replacement plugs with wrenches on Amazon and other locations, probably also at any RV dealer. That said, I think this is a standard pipe thread so a brass plug from someplace like Ace Hardware should also work fine, just make sure to use teflon thread tape and don't over tighten.

Good luck!

[Fungus]

What have you tried?

I assume that the plug is intact and only the head twisted off.

Spitballing here…

If it were me, I might heat the tip of a flat screwdriver. Nylon melts at a shade more than 500F. Press a slit on the plug. Let the slit harden. I have not tried this.

Or, lightly tap a small chisel into the nylon. Twist.

[SlowPokePete]

Can you drill two small holes and use a spanner time tool ?

SPP

[Dan_Rox]

I had the same thing happen a couple months ago. The local Ace Hardware had the extraction tool right next to the replacement plugs

[Runamuk13]

If it is like my water heater, there is very little room to work around the plug.

PVC plastic will deform at around 165 degrees. I would heat up the tip of a small flat blade screwdriver and slowly and carefully and gently try to insert it between the plastic and the threaded part of the water heater. Let the heat do the work. Slowly try to "collapse" the remainder of the plastic plug. You'll need to heat the screwdriver back up often. Eventually, you'll be able to pull or twist the deformed plastic piece out with needle nose pliers.

A hair dryer on hot aimed at the plug might help keep the plastic hot enough to deform. But be careful not to melt wiring or other stuff.

When you get it out, go to any hardware store and buy a 1/2" PVC male plug in the plumbing section.

Or better yet, buy a Showerhead Shut Off Valve. Then you can easily drain your hot water tank whenever you get the urge.

Good luck.
Post to this thread and tell us how you fixed it.

[Lily&Me]

This happened to us in Louisiana years ago.

We went to a plumbing supply store, they sold us the needed plug and told my husband how to remove the other.

Good luck,

Maggie

[ITSNO60]

Originally Posted by Runamuk13

Or better yet, buy a Showerhead Shut Off Valve. Then you can easily drain your hot water tank whenever you get the urge.

.

I've thought about this but I'm thinking the reduced diameter would hinder a thorough flush of the chunks of sediment. Would also want to use brass on my AL tank as AL and SS don't play too well together. Have you done this?

[JCWDCW]

Agree with the above
If I had a wide blade screw driver or even a wood chisel I would push/drive it into the hole to get a purchase on the plug and twist it out

[delrossa]

I would only use a Nylon plug like the original. I was informed years ago that this nylon plug is an extra safety release in case the pressure release valve fails.

[Too tall]

Originally Posted by Wyokirk

On the road in Northwestern Minnesota. Needed to drain hot water tank today. When I reinstalled the plastic plug, the head broke off, leaving the threaded portion of the plug with about a 1/2 inch hole in the middle - heater won't hold water. Tried to remove with the tools I have - not luck. I don't want to get too aggressive and ruin the threaded portion in the hot water heater.

Also, on our way to Canada to be on the Polar Bear & Northern Lights Caravan - need a solution soon.

Questions:
1. Has anyone had this happen to them and how did you remove the remainder of the plug?
2. If you haven't had this occur, any ideas on removal?
3. Any RV repair location in this area (Northern Minnesota or Southern Manitoba you would recommend?

Thanks in advance for replies

https://www.amazon.com/Orbit-Sprinkl...c-6ce62808241a

[ITSNO60]

Originally Posted by delrossa

I would only use a Nylon plug like the original. I was informed years ago that this nylon plug is an extra safety release in case the pressure release valve fails.

I think that is internet lore that has been passed around. I concluded that the real reason for nylon is to prevent damage and galling to the tank threads by repeated removal and installation by the average Joe. In fact an RV repair guy said that on another forum.
If it were for an extra safety why wouldn't they do the same for home water heaters. Also I'll bet that nylon plug can hold more than enough pressure to allow the tank to rupture instead.

[emelaich01]

Get a large, flat-tip screwdriver and heat the end with a propane torch or over a gas stove for a minute or two. Once hot, the tip should melt its way into the plug; hold until it cools a bit. You'll have created a slot in the stub and should be able to unscrew it.
Got to your hardware store and they'll have a nylon plug with a square head and 1/2" NPT thread for about $2 or less. Reinstall with Teflon tape and you'll be back to hot showers in no time!

[kb0zke]

Lots of good ideas here. Take a look at your tool box and see what you have that might help. The biggest concern is not damaging the threads on the hot water heater. The plastic plug is trash anyway, so whatever you need to do to get it out is just fine.


Once you get it out, make sure that the treads on the hot water heater are clean and smooth before you put the replacement plug in. Then, don't over-tighten.

[Daquenzer]

This is an interesting problem. Following closely. Let us know how you get it out.

Yes. Do NOT over tighten. I only tighten so no water leaks out. I would also assume you use plumber’s tape or something similar.

[pmclemore]

This happened to me on the road last week. Although I have removed and replaced the plug many times over the years, this was the first time i attempted to tighten the plug when the water heater had hot water in it. Combined with the age of the plug, the fact that it was hot caused it to break off with the slightest pressure.

Went to Lowe's and bought some easy-outs. Failed - the inside of the plug was too soft for the easy-out to grip. Only solution was to use a sharp screwdriver and chisel out a line. Then I could grab what I could and tear the bits out.

As for the plastic plugs - the ones you find in a hardware store are not strong enough and easily distort. Buy some teflon thread tape and then get a brass 1/2" pipe plug and be done with it.

Good luck. Getting the old plug out is a bear. Get a stool and make an hour of it.

Pat

[Wazbro]

A rarely followed suggestion/instruction from Atwood (before being bought by Dometic) was to replace the plastic plug every time you removed it. Seems like overkill, but I suppose using the same one for 10+ years and complaining it failed is to.

[Wyokirk]

All – thanks for all the suggestions. I apologize for the slow reply, but the Campground we were in had limited cell and WIFI.
On Friday (the 13th) we drove out of our way to an HD and purchased the pipe nipple extractors as suggested, and also the in the link below. I tried both in the HD parking lot with no success. We then headed to our destination and arrived about 7PM.
The next AM, I was taking a walk and ran into a friend from a previous caravan and discussed the situation. We tried the pipe nipple extractors and the smaller of the tools in the link below(Husky Internal Pipe Wrench Set) into the hole in the plug without success – just not enough material remaining. We then took the next size of the Husky Internal Pipe Wrench Set and using a hammer, tapped it into the hole and turned with a socket/extension/ratchet. After a couple of attempts, the broken plug started to turn. Took several cycles tapping in and turning to finally remove the broken plug.
I then flushed the hot water heater in case some pieces of the plug were inside. I also cleaned the threads before I carefully installed the new plug – with Teflon tape. I tightened carefully. All good, no leaks.


https://www.homedepot.ca/product/hus...set/1000828290

[ITSNO60]

Originally Posted by Wyokirk

All – thanks for all the suggestions. I apologize for the slow reply, but the Campground we were in had limited cell and WIFI.
On Friday (the 13th) we drove out of our way to an HD and purchased the pipe nipple extractors as suggested, and also the in the link below. I tried both in the HD parking lot with no success. We then headed to our destination and arrived about 7PM.
The next AM, I was taking a walk and ran into a friend from a previous caravan and discussed the situation. We tried the pipe nipple extractors and the smaller of the tools in the link below(Husky Internal Pipe Wrench Set) into the hole in the plug without success – just not enough material remaining. We then took the next size of the Husky Internal Pipe Wrench Set and using a hammer, tapped it into the hole and turned with a socket/extension/ratchet. After a couple of attempts, the broken plug started to turn. Took several cycles tapping in and turning to finally remove the broken plug.
I then flushed the hot water heater in case some pieces of the plug were inside. I also cleaned the threads before I carefully installed the new plug – with Teflon tape. I tightened carefully. All good, no leaks.


https://www.homedepot.ca/product/hus...set/1000828290

Glad you got it. I have a set of Rigid US made internal pipe wrenches that have got me out of a jamb more times than I can count. I won't say how much my Rigids were, but just one was a lot more than that whole set of Husky and that was 25 years ago!

This was shared on another forum a few days ago and I'm in the process of doing it myself right now.

[richard5933]

Originally Posted by pmclemore

This happened to me on the road last week. Although I have removed and replaced the plug many times over the years, this was the first time i attempted to tighten the plug when the water heater had hot water in it. Combined with the age of the plug, the fact that it was hot caused it to break off with the slightest pressure.

Went to Lowe's and bought some easy-outs. Failed - the inside of the plug was too soft for the easy-out to grip. Only solution was to use a sharp screwdriver and chisel out a line. Then I could grab what I could and tear the bits out.

As for the plastic plugs - the ones you find in a hardware store are not strong enough and easily distort. Buy some teflon thread tape and then get a brass 1/2" pipe plug and be done with it.

Good luck. Getting the old plug out is a bear. Get a stool and make an hour of it.

Pat

The teflon tape won't prevent the brass from being in contact with the aluminum of the tank, and eventually they will start bonding together.

My solution was to lay in a supply of NOS plugs which were made before Atwood sold out to Dometic. The older Atwood plugs had a slight taper to them and sealed much better. The newer ones and the common ones found in hardware stores have nearly parallel sides, so no matter how firmly they are turned in they just don't provide a watertight seal under all conditions.

Sometimes I think I could mold a better plug myself as a DIY project than the ones I see sold nowadays.