Quote Originally Posted by TomJ View Post
My pan is a new aluminum one and of course the plug is new too. I tried plastic washer, metal washer with silicon, and the copper washer. I am going to try that black fiber that MelloYello mentioned and maybe a new plug too. Very frustrating as my old stock oil pan did the same thing.
Tom,
It's very easy to over tighten an oil drain plug. Instructions I've seen say to snug it, then put 1/4 turn and stop. The GM spec for a pan drain plug is 18 ft-lbs, which is not much. You may be distorting the washer too much, or you could have pulled the threads up crowning the sealing surface on the pan if you got really heavy with the wrench.