went to change oil on my bus last weekend and had to pull off the plate on the bottom since it didnt have the oil plug. drained oil which was a task due to the windy conditions... a tad messy. i had bought a new plate with the drain hole and after cleaning off the bottom where the old seal had stuck i went to tighten things up.  i went in a star like pattern and noticed one of the studs was a bit longer.  as i went the stud stuck out longer each time i tightened it it never got real tight or pulled the plate to the engine. i finally decided to leave it be and tightend up the others.  it looks like its started to pull out, and i need to know what size helicoil i need to get to repair it. cant put oil in or it will just leak out, and cant really get it moved to anyone to get it done. :'(

I've used the step studs to make this repair before. ACE hardware used to carry them.

These studs get overtighened by almost everyone who touches them.  I don't remember the spec. off the top of my head, but it's only a few INCH pounds.  Overtighten them will not only pull the studs out of the block, it'll warp the sump plate and cause it to leak.