I guess I'll introduce myself first. I've been reading this site before I bought my 2003 WRX wagon back in 2003. I haven't had the need to post because what I have to say has already been said. Nasioc is a fantastic research tool (just as long as you know how to search). Anyway, I hope you can help.

So I was changing my oil, and I was putting the plug back on when, I'm assuming, the plug failed. Yes, I was using a torque wrench and the gauge was reading 25-26 #ft when it got really easy to turn. I immediately tried to back the plug off and it just spun in place. I then called Webster Groves Subaru and they told me to try to pry it off while unscrewing the bolt. That didn't happen. I then had a flatbed tow my car the local Honda dealership because Webster Groves is in St. Louis and the car is 100 miles away in Cape Girardeau, MO. The service manager at Honda worked on my car and, after getting the plug off, he concluded I need a new oil pan because the threads are shot. They're waiting for the parts as I write this.

I've been conversing with SOA and they tell me that an "authorized Subaru dealer" needs to look at it, if I want it covered by warranty. Give me a break, it's an oil pan. I don't want my car shipped 100 miles away from my access. It's already bad enough that I have to go to school in Rolla while only my mom can check on my car. If my car is in St. Louis, I'm still 100 miles away from it.

I know this is a lot of jargon, and if you have any questions, just let me know. And, yes, I have changed my oil several times before and this last time was my first encounter.

I don't know the price of Honda installing a new pan but doubt SOA will cover it. If the dealer had done the oil change it would be the techs fault. Since you were holding the wrench I think you will be stuck with the bill. I would have Honda do it since if you tow and its not covered you will have the towing charge also.

/applause for long-time search user first time poster

I agree with cnminter - since you are the one who did the oil change they will probably blame you for trashing the threads.

Wonder if you can maybe tap the hole instead of getting a whole new pan? Have to be careful about the metal shavings though....

Fumoto valve anyone?

twa,
It may also have been whoever changed the oil the previous time that stripped the threads. Unless that was a Subaru dealer, I don't see how Subaru would agree to pay anything. Therefore, don't worry about getting Subaru to pay, worry about getting it fixed properly but for a reasonable price.
From your description, and based on my own sad experience with my Miata, I'm going to guess that the threads in the Subaru oil pan are really in a cylindrical steel insert in an aluminum oil pan. I think that what happened was that torquing the plug too tight caused the insert to turn, loosening it in the oil pan. That would explain why the plug turned freely, but couldn't be pulled out.
The expensive repair would indeed be to replace the oil pan. However, another long-term option is to repair the damage by using a very-high-quality oil & temp resistant epoxy to lock the sleeve back in place. To minimize the chance of this happening again in the future, you could go one step further and install a Fumoto valve.
If I'm wrong and it's just the threading in the insert that is shot, again the repair option would be to use an epoxy to permanently install a Fumoto valve. In either case, I'd have an experienced mechanic do the install so you have recourse in case something goes wrong down the line. I would expect to pay less than $100 for everything.

The pan is stamped steel and they are relatively inexpensive. Having the Honda dealer replace the pan was/is the right thing to do.

You could just install one of the rubber expandable plugs that are sold at most auto parts stores either as a permanent fix, or as a temporary one until you either get a new pan or helicoil the old one.

I suggest you read the section in your Warranty and Maintenace booklet titled EMERGENCY REPAIRS, because it seems to apply in your case.

Fumoto valve anyone?

BUy a Fumoto Valve and either have them put it on or you put it on...and this will never happen again.

www.fumotovalve.com

The pan is stamped steel and they are relatively inexpensive. ...
Thanks! I guess it can be dangerous to depend on other makes' designs when repairing a Subaru... :)

I have a brand new oil pan I never used I'll sell you for $40 and free shipping. You can paypal me at jikhead@hotmail.com