Removing a Rusted Freeze Plug

[Grizz]

I was driving home the other day when I noticed a temp spike.  I had steam coming out from behind the motor when I opened the hood.  i was thinking the worst. I thought I had a blown head gasket.  i let it sit for 30 min then i checked th oil and found there wasnt any contamination.  I got the bronco home and started looking into what was going on.  Naturally i filled the raditor back up to see if i had oil in the water.  As soon as i started I could hear water pouring out.  i quickly crawled under to see a little fountain of water coming out of a freeze plug. 

The location of the plug is next to the exhauset manifold and oil dipstick.  i have tried many methods of removing this without any dismantling to no end.

Yesterday I finally broke down and dismantled the driver side exhaust to give me more working room.  still cant get this thing out.  my idea is the plug and rusted to the block and i may need to get a hacksaw in there.

So to make a long story short any ideas on how to remove this thing?

 

[miesk5]

yo GRIZZ,

See Bronco-F-Series Workshop Manual (PARTIAL) http://www.diesel-dave.com/vehic/manual/stj/stjleft.htm

R&R @ http://www.diesel-dave.com/vehic/manual/stj/stj30027.htm

Same as your year.

 

[Grizz]

thanks for the insight.  I have had numerious people recommend the slde hammer to me.  The only thing i see that could be a problem is that the motor is still in the truck.  I have removed the manifold that sits right next the plug but the frame rail is less than a foot away. Any action with a slide hammer I feel is not possiable.  As the pic shows, there are holes in the plug, so putting a ***** through it would just compermise the plug even more.  Today i am going to soak the area with PB Blaster to loosen the rust built up around the plug and hopefully I can use a cotter pin extractor tool to pull it out.  Like i said though not much working space.  Dont have the resources needed to pull the motor so thats not even an option.
 
On a seprate note when i removed the manifold there was no gasket inbetween the head and manifold.  Is this a factory install or just owner/shop neglect. 
Should I use a gasket when reinstalling?

 

[Bully Bob]

I've used screwdrivers or a brake adj. tool.  Going up thru what's left of the center & prying it out, even if it comes out in pieces.

(similar to poping out a grease seal)

In one unusual case I actually pushed the old one up inside & installed the new one. It couldn't go anywhere & could be removed on a rebuild. Or once pushed in.., needle nose pliers can pull it out.

Once out.., polish the hole. A dremmel with a mini wire wheel works good.

 

[Bully Bob]

Another method is Dremmel also makes a mini cut-off wheel.

You could pull out most of the center of the plug.., weakening it.., then grind a grove across the wall side of the plug.

(being careful not to scar the actual block)

Then small chisel away 'til it cracks lose.  Maybe grind two slots if needed.

 ALSO; Factory does mate metal to metal in many cases.., no gasket.

 

[Grizz]

I finally had success last night.  i dont have a dremel but i did use just the blade of hacksaw and weakened the edge.  once that happened a little tap tap and it was out. 

today after work i will have my bronco going agian.  just in time for the wet weather heading our way and the muddy leavee to play in.

thanks all for the ideas.

now to move on and figure out the vibration coming from the rear end, but that should probably be a new thread.

 

[Jeff Ogden]

If you put the feeze plugs in the freezer over night they go in easier.