NHTSA Complaint #10048882 — 2003 VOLKSWAGEN PASSAT

ON NOVEMBER 21, 2002, MY 2001 VW JETTA GLS 1.8 TURBO LOST THE OIL DRAIN PLUG ON THE HIGHWAY. I STOPPED THE CAR AS SOON AS POSSIBLE BUT THE ENGINE AND TURBO WERE DAMGED SEVERELY AND HAD TO BE REPLACED. TOTAL COST $6,500. I WAS NOT REIMBURSED. I REPLACED THE JETTA WITH A 2003 VW PASSAT W8. ON NOVEMBER 23, 2003 THE OIL WAS CHANGED BY THE DEALER AND THE DEALER CONTENDS THAT THE OIL DRAIN PLUG WAS TIGHTENED TO FACTORY SPECIFICATIONS (20 NM), HOWEVER THE CAR HAD AN OIL LEAK COMING FROM THE DRAIN PLUG. THE DEALER REPLACED THE PLUG FREE OF CHARGE. HERE IS WHAT IS COMMON TO BOTH SITUATIONS: BOTH DRAIN PLUGS WERE TIGHTENED TO AT LEAST THE FACTORY SPECIFICATION (I CHANGED THE OIL AND ALWAYS USED A TORQUE WRENCH ON THE JETTA) AND BOTH HAD DRAIN PLUGS PULL AWAY FROM THE PAN. I DO NOT KNOW WHAT THE ROOT CAUSE WAS BUT I HAVE A HYPOTHESIS ON TWO IMPORTANT VARIABLES: (1) BOTH PANS ARE MADE OF ALUMINUM, WHICH CHANGES SHAPE EASILY WITH TEMPERATURE CHANGE, (2) THE DRAIN PLUG IS MANUFACTURED IN SUCH A WAY THAT THE WASHER (SEAL RING) CANNOT BE REMOVED AND REPLACED. IF THE SEAL WERE WARPED OR DAMAGED IN SOME WAY (PERHAPS OVERTORQUING OR DROPPING THE PLUG) IT MIGHT NOT SEAL PROPERLY. WOULD LIKE FOR SOMEONE TO CONTACT ME AS VOLKSWAGEN HAS BEEN LESS THAN HELPFUL (ESPECIALLY WITH THE JETTA).*AK