Help. Freeze plug removal problems
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New User
Joined: Nov 2002
Posts: 8
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From: California
Help. Freeze plug removal problems
Good morning I have a 91 bronco. there is a leak in the freeze plug that faces the firewall. I was able to punch a hole in it from under the truck to attempt to get it out got a big ol screwdriver in the hole but when i turned it the hole opened up farther and the piece bent inward.
Is there a way to get to that plug? is there a special tool to get at it from the top.
any suggestions would be helpful
Is there a way to get to that plug? is there a special tool to get at it from the top. any suggestions would be helpful
Senior User
Joined: Feb 2002
Posts: 470
Likes: 1
From: Mount Prospect, IL
Help. Freeze plug removal problems
get back under there, and take your hammer and screwdriver with. oh yah, better bring some vice grips too.
I assume you have a nice tear right in the middle of the freeze plug. Now take your screwdriver, and place the tip right on the lip of the plug, trying to angle it slightly away from the block. Each time that you hit the screwdriver, it is going to glance right off this lip, and you will have to reposition it. eventually the lip will start to pull away from the block. At that point, just try and wedge the tip of the screwdriver between the lip and the block, and try to force the lip out a little more. Take your vice grips, and tighten them like hell until you almost get a bloodblister when they finally clamp down. This should do it.
good luck
I assume you have a nice tear right in the middle of the freeze plug. Now take your screwdriver, and place the tip right on the lip of the plug, trying to angle it slightly away from the block. Each time that you hit the screwdriver, it is going to glance right off this lip, and you will have to reposition it. eventually the lip will start to pull away from the block. At that point, just try and wedge the tip of the screwdriver between the lip and the block, and try to force the lip out a little more. Take your vice grips, and tighten them like hell until you almost get a bloodblister when they finally clamp down. This should do it.
good luck
Thread Starter
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New User
Joined: Nov 2002
Posts: 8
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From: California
Help. Freeze plug removal problems
Thanks, The problem that im having is that it is the plug that faces the firewall and there is VERY little clearance there like 6" at best. someone suggested that i drill a hole in the firewall to get to the plug. I was hoping that there was some funky tool out there made for this .
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New User
Joined: Nov 2002
Posts: 8
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From: California
Help. Freeze plug removal problems
Thanks i will give that a shot. there is a automotive store that opens at 9 that rents tools so im hoping that they have something that will work. if i can get to the very edge of the plug i might be able to tap it sidways. Off to work on it
later
later
Post Fiend
Joined: Nov 2002
Posts: 9,987
Likes: 7
From: Memphis, TN
Help. Freeze plug removal problems
Just use the screwdriver to push one side of the plug INTO the block. You can do that with the screwdriver at a serious angle; just try not to mar the block. Even if the whole plug goes into the block, it won't fall far and you can grab it & rip it back out. If the block IS marred, just smooth the burr back down and put some silicone on the new plug.
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New User
Joined: Nov 2002
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From: California
Help. Freeze plug removal problems
All righty then. after working all day on it i finally got the damn thing to seal. actually had more problems with replacing the thermastat. put the new gasket on and the thing leaked. had to pull it off again Major pain since the water pump and the roter are in the way not to mention some control thing with a big plug that sticks right in the way. Ended up cutting a hole in the firewall to get a straight shot at the freeze plug. That was interesting. well all is running well now and no leaks.
Thanks for all the advice.
Mark
Thanks for all the advice.
Mark
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Senior User
Joined: May 2002
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From: Mountain State
Help. Freeze plug removal problems
Hi, a freeze plug is a filler in the block. There are several on the sides where the water jacket is. It's where the coolent flows arouudn. The idea is to have a weak place to blow out if the coolent freezes. It saves the engine from cracking.
Posting Guru
Joined: Jul 2002
Posts: 2,205
Likes: 1
From: Vancouver WA
Help. Freeze plug removal problems
Unfortunately, the cracked 429 block I had in my garage for a long time is proof that they don't always prevent cracks. Stupid cold weather. Blew a hole in a radiator hose. Taped it up. Found a housing development under construction. Luckily, one of the houses was complete enough that it had water. Filled up the radiator one quart at a time. Not an easy task since the engine was hot enough that most of the water steamed off. Finally got it full. Drove it home. Got up the next morning to work on it. The crack was big enough that water would leak out almost as fast as the hose could fill it up.
Post Fiend
Joined: Nov 2002
Posts: 9,987
Likes: 7
From: Memphis, TN
Help. Freeze plug removal problems
You probably cracked it when you poured cold water into a block over 300°! 
When you overheat, if there's still flowing water, you should leave the engine running & refill slowly. If not, stop the engine & let it cool to no more than ~180° (too hot to touch, but spit doesn't boil) before slowly refilling with the engine running.
When you overheat, if there's still flowing water, you should leave the engine running & refill slowly. If not, stop the engine & let it cool to no more than ~180° (too hot to touch, but spit doesn't boil) before slowly refilling with the engine running.
Posting Guru
Joined: Jul 2002
Posts: 2,205
Likes: 1
From: Vancouver WA
Help. Freeze plug removal problems
I did refill it slowly, the engine was running, and it didn't leak the 20+ miles it took for me to drive it home. Maybe I should have mentioned it was in the low teens overnight, and the water in the radiator was frozen solid in the morning. I waited for things to warm up and thaw out, and lo and behold, a big puddle of water showed up on the driveway.
Posting Guru
Joined: Jul 2002
Posts: 2,205
Likes: 1
From: Vancouver WA
Help. Freeze plug removal problems
True, but at 3:00AM, in the freezing cold, and after a "spirited" evening with the guys, draining the radiator was the last thing on my mind. Trying to make it in the house and into bed before passing out was top priority.:+