frost plug replacement

[gleem]

i have tried to replace the the frost plug on my 4l soch 95 ford falcon. How hard should it be to put a frost plug in in terms of force? as i have never done one before. i have the right size (40m). But theres a coolant line some what in the way so i cant get a good straight hit but with the force ive given it should be more than enough. it fits just over 1/3 of the way in before forcing it.

i did this the first time but couldnt get the top in fully as i didnt put it in straight and the first time i redlined it it popped off.

i got another one today but with the same result.

Just in general, to get a frost pug in do you need to give it a good wack?

[snwtoy]

The one time I replaced frost plugs, I used a rubber or wooden mallet, and yeah just gave it a good whack. The engine was out and completely stripped down tho, so nothing in the way.

[AE82 FXGT]

I redid all the frost plugs on gze when it was out, so I had nothing in the way. Do you have a brass frost plug? The steel ones rust, I don't even know why they make them.

You would probably have to take that line off (bypass line from the back of the waterpump?), get a replacement o-ring for that too as they tend to leak (especially on the au/ba/bf).

But yeah, a good few smacks with a hammer should do it, I also put some sealant around them before I put them in.

[gleem]

it seems the coolant line goes from the water intake ( so the cooled water) and runs to the trans. its such a mission to take that line of so im going to cut a section and replace with a hose and heat wrap it.

[Flannelman]

I used a large socket by placing it in the frost plug and hit the socket. That way its easyer to hit in straight.

Is the hole in the block corroded, rust build up or part of the old frost plug still in the block? If so it needs to be removed.

Sealant would be a good idea too. Tap (or smack) the plug in till its flush with the block.

[AE82 FXGT]

if it goes to the trans itll be a trans cooler line. does it go to the radiator? if it is you will need to flare the ends of the pipe if you are going to put a hose in it.

[iOnic]

They're a bit of a pain to do on the Fords but it is possible to do without removing the line. Just make 100% sure that the hole is clean and there are no bits of the old frost plug in there and then use a socket to drive the new frost plug in with a rubber mallet. Also make sure the frost plug is 100% square on the hole - if it goes in on a slight angle you'll never get it completely in. You have to do it a bit at a time - you won't get a single solid hit on it because of how little room there is.

[gleem]

as i failed the first time i sanded it back real good this time. i tried buying a plug one size down but they dont make them. only a a good few mil smaller. i do do it with a socket but eventually i fail. if i cut the line i will use a socket and small hammer so i can get a good hit. any suggestions on how to get the old one out? it doesnt come with plyers. i have relined it a few times but it doesnt pop out?

[allencr]

how to get the old one out? i i have relined it a few times but it doesnt pop out?

What's 'relined''?
Are these cup type, with 90 degree sides or the dish type, a convex dish that expands when it's flattened a bit? It sounds like the cup type, if so hit it on the top or bottom driving that side in & rotating the opposite side out. Grab the side that's sticking out with pliers/visegrips. If it's punched in on either side, it usually hits the cylinder so that's why I'd use the top or bottom. Sealant/gasket cement not RTV, to seal its press fit/close tolerance.
Also, they make rubber ones that expand with a nut that wiil do the trick, if you can get one in mm.

[gleem]

redline. Did a huge stand still and that did the trick. Got a new one again so will try it this time after cutting the coolant line