Installing frost plugs

Removing an old freeze plug requires a punch and a hammer. Some people use screwdrivers, but we all know that screwdrivers are for screws , nothing more. Use the punch on one lip of the plug, and then hit it with the hammer until it folds over.

Once it is folded over, you can use pliers or vice grips to pull it out. Inspect it and look for signs of cracks.

You just want to knock off any loose rust or sealant. Clean the surface with some brake cleaner and wipe dry.

Then prep the plug with some Permatex Form-A-Gasket 1 sealant. This product is designed for freeze plugs and other press-fit applications, as well as gaskets. Just a thin coating is all you need. Align the plug into the hole and press it in by hand. You should be able to get it to hold by hand. Next, use a bearing driver and a hammer to drive the plug into the hole. You want to drive on the outside of the plug, not the inside. Replacing freeze plugs is not hard, but getting to them can be really tough with the engine in the vehicle.

Know How. A life-long gearhead, Jefferson Bryant spends more time in the shop than anywhere else. His career began in the car audio industry as a shop manager, eventually working his way into a position at Rockford Fosgate as a product designer.

In , he began writing tech articles for magazines, and has been working as an automotive journalist ever since. Jefferson has also written 4 books and produced countless videos. Jefferson operates Red Dirt Rodz, his personal garage studio, where all of his magazine articles and tech videos are produced.

Your email address will not be published. Save my name, email, and website in this browser for the next time I comment. Skip to content Your engine block is full of holes to the outside world. This is what happens when a freeze plug fails to pop and the water in the block expands.

This small-block Chevrolet engine has two missing freeze plugs. If you left these out and put it in the car, the coolant would just pour out all over the floor. Then we prepped the plug with some Permatex Form-A-Gasket to ensure we have a good seal.

Next, the plug was installed into the block by hand. Make sure it is square to the hole. But I'm getting tired of always making new tools, especially if there is an easier , possibly , better way to get the job done.

Yes there are the screw in plugs, but that is a bit unrealistic for your average shop to do. Suggestions, opinions or experiences are all welcome. Thanks guys. Re: installing brass frost plugs Post by David Redszus » Thu Jun 05, am You might want to check to be sure the freeze plugs actually are brass.

If they are, you will create a strong galvantic couple. For a cast iron block, a steel plug would produce the lowest galvanic couple but the steel might rust. Very often steel plugs that have been yellow cadmium plated are used; they look like brass. Re: installing brass frost plugs Post by engineguyBill » Thu Jun 05, pm Proper installation of expansion plugs is very important, regardless of the material.

First, the hole must be clean and devoid of all rust and corrosion. Coat the plug and the hole with a light coating of clean oil, such as engine oil - never use silicon or RTV on the plugs. Drive cup plugs with a tool that fits loosely inside the cup never drive the outside edges of the cup , until the edges of the cup are adjacent to the machined opening of the hole. Three small holes can be drilled next to the hole and tapped for small screws and washers if additional insurance is desired, however this is usually not necessary if the plugs are installed correctly.

Personally, I have never had any problem with bi-metal material degradation when installing brass expansion plugs in cast iron or aluminum blocks. Re: installing brass frost plugs Post by novadude » Thu Jun 05, pm Why do so many use brass plugs? I've always used steel. Even in engines where the cooling system is not well maintained, I've seldom seen the cheap common zinc-plated steel plugs rust through. I guess I've never quite understood the advantage of brass?

Steel plugs install pretty easy just using an appropriate size socket as a "driver". Re: installing brass frost plugs Post by avengerengines » Thu Jun 05, pm novadude wrote: Why do so many use brass plugs?

Re: installing brass frost plugs Post by Fordracer » Thu Jun 05, pm Brass for marine for sure. I've even had some old time marine guys mention cylinders rusting pinholes through on some BBC stuff that gets drained every winter. Personally, I prefer the brass because it gives not only a better visual appeal but also shows you cared enough to spend the extra couple bucks on plugs.

The brass plugs I use are either Dorman or Pioneer and usually don't have issues with them sealing or being to loose in the core holes. Install them with Permatex Avation sealer.

I've seen the galvanized ones rust and some look pretty bad in a short time in systems when using water for cooling. Re: installing brass frost plugs Post by 2. I've seen TOO many brass plugs blow out.

As has been said, Clean, clean, and then I install them with JB weld. He was OK but it shook him up pretty badly. From that day forward if we do a track only build we pin the plugs see the photo below. I believe many circle track racers have these rules in place already. Every build here gets at least brass behind the bell as a minimum.