how to get plug out of intake?

[scott s]

anyone have any ideas on how to get one of those steel coolant plugs out of a aluminum intake mainfold thats been there forever and will not budge?? It has the 3/8 drive recessed square hole but i broke 2 tools already thanks

[firez]

I had to spray some liquid wrench on the backside of the intake. It seemed to loosen the threads up but took a couple days of soaking the threaded area with liquid wrench.It will come just takes a couple times soaking it.

[L78steve]

It will probably take the aluminum threads with it. This is the only way I found to work, Drill a 3/8 hole in the center of the plug then get a jig saw and cut outward toward the threads being very careful not to hit the alum. then take a chisel and hammer and carefully collapse the plug. This will break the bite the two metals have with each other. It works with cast parts also. If you slightly nick the aluminum, sealer will cover it.

[m22mike]

Good advice by Steve, have used this method more than once. Works on the water pump fittings too.
Sometime's I make 3 cut's. Take something like a old pin punch 1/4 or 3/8's and sharpen it so it digs in to the plug.
Work slow.

[scott s]

Thanks guys thats the only way i could think of also espically when the eng is all together..

[67Z24rag]

Having worked for an automotive engine rebuilder (Speed Shop ) for 20+ years I was taught some neat tricks by the older guys. Heating up the steal plug itself with an acetylene torch, not the manifold and dousing the plug with paraffin, clean candle wax, will loosen just about any block plug or manifold plug.The paraffin works its way between the threads and lubricates them. My experience was they came out like they were just freshly lubed.This worked on many rusted blocks, heads and intakes that had galley plugs, especially all the little galley plugs in BB Chevy's blocks.Most people try to expand or heat around the plug, that doesn't work in this case, concentrate on the plug with the heat. Worth a try. Jon

[markjohnson]

I've been down this road before and those plugs can be a real SOB. Take care and patience with whatever you do.......I've seen some nice, rare intakes really mutilated sometimes because of this.