Question: have you ever had to "repair" (aka modify) an oil dipstick before? Mine got stuck, finally got it out, but it won't go back in.

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https://m.media-amazon.com/images/I/21pKt6mv5aL._AC_.jpg
The part in yellow is modified by sanding it down with a file.

It's a rather strange problem. The oil dipstick became stuck, I had to use a tool for leverage to pry it out, and of course it won't back in. So, either the dipstick became 'defective' somehow (did it expand in size over time?) or the dipstick tube contracted somehow (did it acquire rust inside or something? It doesn't appear to the naked eye to be so.)
As a first step, I replaced the dipstick with a Dorman unit from Autozone for 14.50$. It did NOT work, same problem.

Solution #1 aka "make the hole bigger": use a drill bit to shave some metal off the inside of the dipstick tube.

Solution #2 aka "make the dipstick smaller": use sandpaper to shave down the size of dipstick

Solution 2 is probably better, for obvious reasons (we don't want metal shavings down the dipstick tube.)

What do you think? This seems to be a really rare issue, and I don't understand how this can happen.
 
Oil dipsticks are very cheap. For my 2006 Honda Odyssey EX-L, I got it from an online Honda Dealer's parts department for only $17.

Probably best for you to just order another one for your vehicle.
Any kind of tampering/adjusting of the old one could give you inaccurate oil level readings.
 
Back in the day I made a dip stick for an AMC Gremlin V8 that had a busted dip stick tube and missing dipstick. I twisted together some bailing wire strands, changed the oil and marked the wannabe dip stick. Better than nuthin'....
 
Oil dipsticks are very cheap. For my 2006 Honda Odyssey EX-L, I got it from an online Honda Dealer's parts department for only $17.

Probably best for you to just order another one for your vehicle.
Any kind of tampering/adjusting of the old one could give you inaccurate oil level readings.
Weird.

Cheap though. Buy a new one. Wouldn't waste 10 seconds on old one.

Already replaced with an aftermarket dipstick-----same problem. I doubt a factory Toyota OEM dipstick will resolve the issue.

I'm mostly just confused about how the dipstick tube can contract over time, it's strange metallurgy.
 
The engine oil dipstick in both my F150s (4.6 2V and 5.4 3V) gets really stuck sometimes. I always assumed the o-ring swells for some reason
 
UPDATE: after a closer look, under powerful light, I can see that the dipstuck tube has RUSTED on the inside....... after filing down the dipstick, I was able to get it to go in and out with ease.

It would have been extremely strange for a metal to have contracted on its own for no reason right? Mystery solved.. :D

The dipstick is important! Without the dipstick, I took a guess about the oil level (it was LOW!) I would have been wrong, though not catastrophically.
 
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