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My car had a leak around the sump plug that I couldn't cure. It turned out to be the braze around the plug boss had a hairlinecrack. I only found it when I took the sump off to check/clean the oil pump strainer.
The problem of BSP taper threads is that they are really only designed for one off use. Once used the male and female threadsare deformed into each other to form a gas or liquid tight joint. Unfortunately, second time around the threads have lost their initial forms and will not produce a perfect seal again (ask any gas fitter - they normally throw second hand fittings away because they are not worth the heartache of leaking joints). I find over the years of frequent oil changes the plug scews further and further into the sump! A temporary solution is to fit a new plug but thesump taper thread is still worn and distorted. Other cars have the better solution of a plug with a proper machined shoulder and brass washer. Works every time, particularly if a new washer is always used.
I dont see a problem of ptfe tapeor thread sealent if it works. I have just bought a new product from Loctite called "55 pipe sealing cord". Its a thin cord which you wind along the thread. Many gas fitters nowswear by it. I'm going to try it next oil change. If I ever have to take my sump off I will braze in the brass washer type plug
The thread in the sump should be BSPP G series parallel and the sump plug should be BSPT (Tapered). The idea is as you said each time it is used the tapered plug moves a little further into the thread to seal it. If the plug has been made to the correct gauge line taper it will take a long time and many 100's of uses to wear this out completely.
I decided to use tape as already stated the plug is going too far into the sump. I reckon I could screw it in completely and lose it if I didn't use tape.
You obviously know your threads! We live and learn. I have fitted new plugs in the past but they still screw too far in. I think over the yearsthe overzealous tightening to seal the plug has damaged the female thread. This may be where theory and practice diverge.
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