yo;
I have info & install Links in my site @
http://www.broncolinks.com/index.php?index=953
such as:
by Steve;
Freeze Plugs & Block Heater
Core Plugs
Removal and Installation
To remove a large core plug, drill a 12.70mm (1/2-inch) hole in the center of the plug and remove with an Impact Slide Hammer T59L-100-B or T50T-100-A or pry it out with a large drift punch. On a small core plug, drill a 6.35mm (1/4-inch) hole in the center of the plug and pry it out with a small pin punch. Clean and inspect the plug bore.
Prior to installing a core plug, the plug bore should be inspected for any damage that would interfere with the proper sealing of the plug. If the bore is damaged, it will be necessary to true the surface by boring for the next specified oversize plug.
Oversize (OS) plugs are identified by the OS stamped in the flat located on the cup side of the plug.
Coat the plug and/or bore lightly with an oil-resistant (oil galley) Sealing Compound E0AZ-19554-B or EZAZ-19544-B or equivalent and install it following the procedure for cup-type or expansion type below:
Cup-Type
Cup-type core plugs are installed with the flanged edge outward. The maximum diameter of this plug is located at the outer edge of the ******. The ****** on cup-type plugs flares outward with the largest diameter of the outer (sealing) edge.
Expansion-Type
Expansion-type core plugs are installed with the ****** edge inward. The maximum diameter of this plug is located at the base of the ****** with the ****** flaring inward.
CAUTION: It is imperative to push or drive the plug into the machined bore using a properly designed tool. Under no circumstances is the plug to be driven using a tool that contacts the crowned portion of the plug. This method will expand the plug prior to installation and may damage the plug and/or plug bore.
When installed, the trailing (maximum) diameter must be below the chamfered edge of the bore to effectively seal the plugged bore.
If the core plug replacing tool has a depth seating surface, do not seat the tool against a non-machined (casting) surface.
CAUTION: It is imperative to pull the plug into the machined bore by using a properly designed tool. Under no circumstances is the plug to be driven into the bore using a tool that contacts the ******. This method will damage the sealing edge and will result in leakage and/or plug blowout.
The flanged (trailing) edge must be below the chamfered edge of the bore to effectively seal the plugged bore.
If the core plug replacing tool has a depth seating surface, do not seat the tool against a non-machined (casting) surface.
Engine Block Heater
1. Open radiator draincock (8115) and remove coolant from radiator (8005) and engine (6007).
2. Remove block heater (6A051). Note the position that the element is pointed (eg. 12:00, 6:00, etc.)
3. Clean the inside diameter of the core plug hole machined surface and hole entrance. Remove any burrs at the hole entrance to avoid damage to the O-ring.
4. Cover rubber O-ring and core opening with a liberal coating of chassis grease (C1AZ-19590-B, C, D, E or equivalent.
5. Insert block heater in core plug hole in the same position as it was removed.
6. Tighten ***** in normal clockwise direction. Torque to 1.6-1.8 N-m (14-16 lb-in).
7. Refill cooling sys
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BY CHILTON;
" Core plugs need replacement only if they are found to be leaking, are excessively rusty, have popped due to freezing or, if the engine is being overhauled.
If the plugs are accessible with the engine in the truck, they can be removed as-is. If not, the engine will have to be removed.
1.If necessary, remove the engine and mount it on a work stand. If the engine is being left in the truck, drain the engine coolant and engine oil
2.Remove anything blocking access to the plug or plugs to be replaced.
3.Drill or center-punch a hole in the plug. For large plugs, drill a 1/2 in. hole; for small plugs, drill a 1/4 in. hole.
4.For large plugs, using a slide-hammer, thread a machine ***** adapter or insert 2-jawed puller adapter into the hole in the plug. Pull the plug from the block; for small plugs, pry the plug out with a pin punch.
5.Thoroughly clean the opening in the block, using steel wool or emery paper to polish the hole rim.
6.Coat the outer diameter of the new plug with sealer and place it in the hole. For cup-type core plugs: These plugs are installed with the flanged end outward. The maximum diameter of this type of plug is located at the outer edge of the ******. Carefully and evenly, drive the new plug into place. For expansion-type plugs: These plugs are installed with the flanged end inward. The maximum diameter of this type of plug is located at the base of the ******. It is imperative that the correct type of installation tool is used with this type of plug. Under no circumstances is this type of plug to be driven in using a tool that contacts the crowned portion of the plug. Driving in this plug incorrectly will cause the plug to expand prior to installation. When installed, the trailing (maximum) diameter of the plug MUST be below the chamfered edge of the bore to create an effective seal. If the core plug replacing tool has a depth seating surface, do not seat the tool against a non-machined (casting) surface.
7.Install any removed parts and, if necessary, install the engine in the truck.
8.Refill the cooling system and crankcase.
9.Start the engine and check for leaks.
http://content.chiltonsonline.com/content/images/8576/images/85763300.pdf
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