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You need to use the torch 'before' you strip the Allen
Now, you need to drill it out
Block plugs are the hardest plugs in the whole world to remove
Use tons of heat first, and use the best tools you have
Most of them never come out
I couldn't leave them there either! I didn't have access to a good torch so ultimately ended up using a carbide burr on my Dremel tool. Slowly and patiently cut it away until I could peel the thread out of the block! Block threads were undamaged and STAINLESS STEEL went back in.
Wonderful
So, that's one more that came out and got replaced the hard way
That makes 3 in 40+ years I've seen or heard about being removed
I quit trying in 1976 with a 289
Basically, futile unless you are willing to grind or torch for hours
I do like newer Toyotas with pet***** on the blocks
I’m sure one of these would work if I needed to cajole an Allen screw out
Topec on Amazon. I think I bought one of all their kits. Rounded head extraction? No problem. The chemicals in our warehouses do a number on plenty of stuff.
I wear a lot of rust dust on my gloves when I finish rounding of a hex head that hydrochloric acid rusted the snot out of.
Last edited by Johnny Paycheck; Jan 22, 2026 at 08:51 AM.
I’m sure one of these would work if I needed to cajole an Allen screw out
Topec on Amazon. I think I bought one of all their kits. Rounded head extraction? No problem. The chemicals in our warehouses do a number on plenty of stuff.
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