Hi Guys,
I have a rusted out freeze plug. It leaks, and I think its due to rust eating the freeze plug so thin it finally popped. What is the best way to remove this plug? It is the forward most on the drivers side of the motor front cylinder area. If I can't get the freeze plug out, can I use JB Weld to repair this leak? I'm thinking my vans cooling system is too rusty and I bought some PEAK radiator super cleaner and flush. I need to fix my leak first but is this product good for cleaning out some rust? Thanks as your experience is always helpful.

 

If it matters my van is a 1994 RamVan 250.

 

You have to replace it, do not use JB Weld. Using that will defeat the purpose of the freeze plug and you can end up with a cracked block.

 

O.K. I don't want to crack the block, so out it comes. Do I just try prying it out with a screwdriver or some such metal chisel or punch? Is there a "proper" way to remove a freeze plug?

 

Yeah, pretty much.

 

Hammer and a punch. Select one spot along the edge of the freeze plug, a position where you have room to position the punch, and hit it. Hammer only that one edge and the plug will swivel in the plug hole or come loose and fall in. Remove with pliers. Install new plug carefully with a round punch (or an appropriately sized socket) and tap gently into place with a hammer.

If you dont have room to hit it squarely this won't work. There are rubber/steel freeze plugs with a bolt in the center that can be installed in tight locations when you don't want to pull the motor.

 

Removing the old plug is easy. Just put a flathead screwdriver on the top of the plug and hammer. The bottom will rotate out and you can pull it out with pliers.

Getting the new plug in is the hard part. It has to be installed perfectly straight, and access to a straight shot is not easy.

They sell the rubber type which expands within the hole by tightening a bolt, but these only last a few years, but are much easier to install if you cannot get a straight shot.

Get a couple extra if you attempt to use the brass replacement plugs. Do not bother with steel plugs.

 

Coat around the edge of the new freeze plug with some RTV sealer. This will aid in sealing, but more importantly it will act as a lubricant and allow the freeze plug to go in with less effort.

 

Thanks for the info guys on removing the old plug and installing a new one. What do you guys recommend to use to flush the rust out of the system.

 

A garden hose and lots of water is usually all you need to remove sediment and rust scale.