Hi everyone,
Title says it all.. The aluminum in plastic threads are so thin, with a little hand pressure the bolt stripped the threads completely in the front oil cooler line during an oil change... with a ton of jb weld.. the oil still finds its way out like crazy... I will need to replace the oil cooler assembly entirely. Does anyone know how to? My workshop manual shows "not ready" for that section... and can't find anyone searching online who's done it.
Any help is appreciated!!

Check out this thread, especially post # 25, as it may help you out. It does not sound too hard and there are good pictures to help you visualize the procedure to remove the stock oil cooler.

https://mbworld.org/forums/c63-amg-w...4o-option.html

Why install a tiny oil cooler again?
Look at the thread Mort posted. You just pay a little bit more and get the most useful upgrade you can do.

I have an E63.. never had over heating... I think there is a second cooler ?
either way, I need to get it replaced and it would be a lot easier if the bumper didn't have to be removed. It's hard to tell from the bottom of the car if I can drop the cooler since its angled.

Have you contemplated getting a helicoil installed. A HeliCoil is a coiled-wire type of thread repair insert used to create internal screw threads to accommodate standard-sized fasteners.
This could save you having to replace the cooler. And it's a very cheap fix.

I did.. I believe the way this cooler is designed.. the drain plug hole is aluminum inside a plastic casing. I'm not sure I can use helicoil..but I would appreciate feedback.

The threads inside the oil cooler are aluminum on my 07 E63, and if my memory serves me correctly, you also have the M156 engine so the oil coolers should be the same. So a helicoil should work for you.
But replacing the oil cooler, would require the engine belly pans and front bumper be removed. I would definitely consider this as an option.

Does anyone know what size helicoil to get? What is the size of the drain bolt?

FWIW ..................Time Sert are much better than helicoil


HeliCoils are springs


See; https://www.timesert.com


Time Sert are solid bushings

Regards

Joseph~

The time sert looks much better than a helicoil.

+1 on the TimeSert

+1 on the TimeSert...

I'm glad that, I read this post. So the next time, I change my oil and drain my oil cooler, I will think about this, and not tighten down the oil cooler drain bolt as much as I used to. Good Lesson to be learned here. ​​​​​​​

Same **** happened to mine just by removing the bolt.