Freeze plugs, any tips?

[capta]

The freeze plugs on our Onan are slowly rusting out one by one. We have spent literally hours trying to replace them and I know there must be a trick to it, but I just can't find any easy way to do it.
We've tried rubber ones but they breakdown in about a year and others (metal) purchased on island that seem correct, but just don't go in properly. We've finally gotten the Onan parts (metal) so we'd like to begin replacing them with these.
Anybody have any suggestions to take the hard work out of what should be a simple job? No mechanic could charge hours of labor per freeze plug.

 

[Ted]

The biggest problem with changing freeze plugs is accessibility. If you have the room, use a very blunt cold chisel and continue to tap the plug in the recessed area near the edge. Continue to strike only one area. The plug will eventually begin to pivot with the half you are hitting going into the engine block and the opposite side will pivot outward. Grab the edge of the plug which is outside the engine block with a pair a vice grips or similar, and pry the rest of the plug out of the block. There are a few special tools designed to install these freeze plugs which makes it easier to get them in square to the block. Again the biggest issue is enough access to position a tool and swing a hammer. See if you can locate brass plugs. They will last a very long time.

Here are a couple of Youtube videos showing the process.

 

[Gunni]

I did that job years ago on an old British engine in place, removal as Ted describes, if they were reluctant I punched the cup with a sharpened chisel and levered them out. Going back in with the new I used a properly size ratchet socket as a drift after cleaning the hole of rust. I believe there was a recommendation for anti-seize compound.

 

[capta]

Thanks guys. If I only had the right tool for every job! I'd bet that lil beauty can't be had or borrowed for 532 miles in any direction.

 

[Bill Roosa]

Your local car parts store will have the socket size you need to "make" the tool. That and a 3/8" extension make a handy tool for insulation. Bring a plug with you to get the size right.