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Oil gallery plugs!
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cdn2a View Drop Down
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Joined: 03 Nov. 2010
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    Posted: 28 Oct. 2014 at 3:02pm
Looking for advice, as I'm just about at my wits end.

I'm rebuilding the engine and cant get the main oil gallery plugs out.
I've ground down an extension, to fit the odd sized square hole.
After using the impact repeatedly I broke off the extension.

I'm about to drill, and try the "easy out" method...
If that doesnt work then hit it with the mig...

My concern is cracking the block since it is tapered thread.

Should I be worried? 

I searched oil gallery, but didnt find anything...
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rocketeer View Drop Down
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Points: 3473 		Post Options Post Options   Thanks (0) Thanks(0)   Quote rocketeer Quote  Post ReplyReply Direct Link To This Post Posted: 28 Oct. 2014 at 3:10pm
Why do you want to remove the plugs?
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cdn2a View Drop Down
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For a proper rebuild.

It was a salvaged engine, it had catastrophic failure of a piston, (it broke between top of the piston and the upper grove) aluminium throughout the engine. Even embedded junk into the bearings...

So I have to assume it has junk everywhere. I want it ALL cleaned out....  
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rocketeer View Drop Down
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Points: 3473 		Post Options Post Options   Thanks (0) Thanks(0)   Quote rocketeer Quote  Post ReplyReply Direct Link To This Post Posted: 28 Oct. 2014 at 3:56pm
OK, well to answer your original question then, yes, you should be worried. Pounding with an impact wrench does run the risk of damaging the block. I would also caution against using heat via a torch. What you might want to consider, and I accept no responsibilities if it doesn't work, is a freeze spray. Google it and research it before deciding but it seems to me it runs much less risk than a torch. As for drilling them out, there is some risk and I would be concerned about the difficulty of finding exact replacements.

http://www.amazon.com/Loctite-996456-Corrosion-Release-Aerosol/dp/B001VXU474#

http://www.marineenginedigest.com/diy/fireandice.htm

http://www.youtube.com/watch?v=b0BaowQvL6c




Edited by rocketeer - 28 Oct. 2014 at 3:58pm
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cdn2a View Drop Down
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Points: 234 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdn2a Quote  Post ReplyReply Direct Link To This Post Posted: 28 Oct. 2014 at 6:20pm
Thanks for the advice, I think I'll try the heat/freeze next, before pulling out
the big tools.

I think this would be the modern replacement if I have to break out the drill.
https://www.vintagejeeps.com/pc-77-28-oil-passage-plug-countersunk-376373.aspx
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TERRY View Drop Down
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376373 in the parts list, 3/8" countersunk plug 2 req.
BOULDER 48 2A
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One of mine was a real bear to get out. Ended up drilling it out and re tapping it. So far so good.
Good luck!
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cdn2a View Drop Down
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Success!!!

I tried to remove the plug by drilling / easyout, heat, cold. Didnt work.

Finally, welded 3/4 nut to plug, big wrench, and presto out she came.
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Nicely Done!  I've really never had success with easy-outs.
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