Core Pluts, and engine removal

[DollyDodge]

Is there a secret to getting the core plugs (Welsh plugs) to seal? My engine had two that were leaking and when I took them out there was a lot of material in the block behind them (looked like sand and metal flakes). Anyway I flushed the engine. Cleaned the seats up, put aviation permaseal (as recommended by our parts shop) and the plugs leak just ever so slightly. The two plugs that leak are on the drivers side, lower two. I loosened the panel over the wheel so I can lift it up, and I removed the oil filter so I could get a good strong whack on the plugs. I built a tool that is just slightly smaller than the plug hole. Any suggestions?

Also, there was a video on this forum showing the engine removal. THe entire front grill, radiator, and wheel wells were removed at once. I can't find that video again. What do you hook the hoist onto when removing the front end that way?

[MBF]

I think you want to use something like a 1/2" round drift to set the plugs by smacking them in the center thereby causing them to dimple and expand tightly against the casting of the block. You may be using something that is too big in diameter.

Once you have the radiator out, I'd set a chain across the top two radiator mounting bolts to use as a lifiting point for the hoist and adjust it accordingly to get the balance that you want. Mike

[oldmopar]

While not original they sell a rubber expanding plug that works well. I forget the actual name.

[PatS....]

What do you hook the hoist onto when removing the front end that way?

I think it would be easier with 3 or 4 people rather than a hoist. It's not that heavy but it sure is awkward and floppy.

Take the tires off before the lift so you don't have to lift over them.

[48Dodger]

Don't know if you're refering to the videos I made....but they might be of some help.

As far as lifting goes, my son and I picked up the front end from the front lip of the fenders.

http://www430.pair.com/p15d24/mopar_forum/showthread.php?t=16161

And this is Dan's Thread about removing his front along with a video.

http://www430.pair.com/p15d24/mopar_forum/showthread.php?t=18010

48D

Edited October 20, 2009 by 48dodger

[DollyDodge]

That is the video I was looking for. It is really helpfull.

As far as the punch for the core plugs. I had made one that was about 3/4 inch in diameter, but the machinist at the machine shop told me to make the punch just a bit smaller than the hole where the plug goes. It still dimples the center. The shop manual that I have says to use white lead to help seal it. I looked up white lead on the internet and I don't think you can buy it in the U.S anymore. I found some for sale in Great Britan for boat restoration. I suspect I will get them sealed eventually.

[48Dodger]

Glad the videos helped!

Here's a recent thread that will help you with your plugs.....note the words "freeze" and "plug" are highlighted in red.

I entered those two words into the search option at the top of the page.

http://www430.pair.com/p15d24/mopar_forum/showthread.php?t=16887&highlight=freeze+plugs

48D

Edited October 20, 2009 by 48dodger

[Zeke1953]

I replaced my core plugs without removing anything from my truck but my oil filter. They come out easily with a self-tapping screw and slide hammer. You have to make sure the ridges where they seat are really clean and then apply a bead of silicone sealer. Be sure the new plugs are installed concave side toward the engine. Then use two hammers; hold a ballpeen against the center of the plug and hit it with a two-pound hammer. You only need about six inches to swing the hammer, the weight of it will expand and dimple the plug. No leaks in over two years. Zeke

[Zeke1953]

Just remembered, I also removed my oil filler tube. All the plugs I replaced were on the driver's side of the engine. Not sure if there are any others under the intake/exhaust manifolds.

[DollyDodge]

Thanks for the link to the previous discussions about the core plugs, and for the advice. I too have taken the oil filter and breather tube off and have good access to the plugs. I took out the plugs I put in that were were leaking and put some new ones back in. I will let them sit until this weekend and put some water in and hope they don't leak this time. I used a dremel tool with a rotary wheel to cut a slot in the installed plugs and then drove a screwdriver into the slot and the old plugs came out easy each time. I then used a utility knife to scrape all the gunk out of the hole, and then used wire wheel on the dremel to clean the opening on the block really well, and used aviation permaseal in the whole. I hope this time they don't leak. I was amazed at the stuff I got out of the block.

I also have taken the gas tank off and cleaned it inside and out. I found a pencil in the tank, and a 1945 quarter in the slot between the floor of the cab and the back wall.

I have taken the master cylinder apart and front wheel cylinders off and ordered kits for all. I homed them out last weekend and there is some slight pitting inside. I hope it isn't so much that they leak. It looks to me like water must have sat on the bottom of the cyliners. Some of the pistons in the wheel cylinders were froze with goo and I had to knock them out with a drift. Old Dolly Dodge is a bit of a mess, but we are progressing. I also got the new bearings for the spun rod, and cleaned up the journal with the crocus (sp) cloth. I am looking to find a micrometer to measure the journal and if it is ok, then I will put in the bearings too, and give her a go again.

Thanks for all your help thus far with the old beast.