A common machine engine might obtain six to eight freeze plugs.
When engine blocks are cast at the factory, natural air holes remain behind as a result of the casting process. The casting holes have circular designs, so that a convenient plug can be installed to seal the hole. Concave and convex freeze plugs, commonly made of aluminum and brass, make these seals possible when they are pressure -fitted to the casting holes. Freeze plugs leak after age and deterioration. A DIY repair person can replace his freeze plugs by following a few steps, armed with some basic tools.
Instructions
1. Place the vehicle in park or neutral, depending upon the transmission type. Use a car jack to raise the front and rear of the vehicle and install jack stands under the frame. Use a strong shop light to help you locate your leaking freeze plug from underneath the vehicle. The freeze plugs sit on both sides of the engine block, usually under the exhaust or intake manifold. Use a pair of pliers to release the petcock drain valve on the bottom of the radiator and let the coolant drain into a pan.
2. If you have clearance problems because of an exhaust or intake manifold, use a very shallow socket and turn the hammer sideways, to afford a larger swing. Tap the freeze plug in until it seats evenly on all sides.5. Tighten the radiator petcock drain plug with a pair of pliers. Adjust the drain pan for any dribbling coolant.
3. Clean the freeze plug hole with a wire brush and rag. Remove all grime and rust from the hole, so you have a clean seat. Smear some Locktite sealant around the freeze plug hole lip. Turn a new freeze plug with the concave side facing you and the convex side facing the engine. Wedge it carefully into the hole. Gently tap the edges of the freeze plug to start an initial seat.
4. Select a socket that has the exact diameter of the freeze plug's outer lip. Place it against the freeze plug and tap it in with a hammer. Wipe the freeze plug with a rag so you can see its outline clearly. Place a long punch tip on the rim-edge of the freeze plug and hit the freeze plug with a hammer. Continue to hit the freeze plug lip until the plug lip flips or bevels outward. Use pliers to pull the plug out of its socket.
Remove the radiator cap and add enough coolant to fill the radiator, as well as the overflow reservoir to its prescribed fill line. Raise the vehicle with a car jack and remove all the jack stands. Start the engine and let it warm up. Use the shop light to check for leaks. Shut the engine off and let it cool. Check the radiator water level again, and add coolant as needed.
