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Discussion Starter #1
I have an 402 engine that is ready to paint but I neglected to remove a plug for the TCS sending unit on the passenger side cylinder head. The plug has a recess for a 3/8" drive. I have tried a breaker bar drive on it, tried using a cold chisel to drive it and it is starting to look a little worn.
Does anyone with their repetoire of experience, had any luck in getting a plug out of a 30 plus year old head?
I am worried about trying an acetylene torch as perhaps the head would crack. If I drill it out, I may lose the water pump.
Some how, some way that plug is going to come out.
Many thanks in advance, John.
 

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PB Blast penetrating fluid??? Helped me out on a few body to frame bolts on my bro-in-laws 40 Chevy. Let it sit overnight and shot it a couple times. Breaker bar and pipe required.
 

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The guys in the dealership where I work weld a nut onto the plug, using a 220 mig or an arc welder. This does 2 things. Heats the plug a bit which helps it come out, and gives you a nut to put a wrench on. They had one a few weeks ago that finally came out when they welded the fourth nut on. (First 3 the welds broke before the plug came out) I wouldn't think this would heat the head so much that it would damage anything.

No warranty of any kind suggested or implied with this suggestion:D

Carl
 

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I could never get the oil galley plugs out of blocks until I started using heat. I use a cutting torch to heat the plug itself. The block also gets hot but the plugs unscrew very easily after I heat them up. Been doing that for many years now with good success. RM
 

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i would think as long as you didn't try to cool the head too fast (i.e. dumping water on it after heating it up) you won't crack it. there's a lot of iron there.
 

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Discussion Starter #7
Thanks all for your suggestions. We tried heating the heck out of the plug but she still wouldn't move. As a last resort I borrowed a candle, let the wax do it's thing for 30 sec and hit the plug again with the breaker car. Out she came like a piece of cake!
John.
 

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