Going to grab breakfast at McDonald's this morning, about an 11 mile round trip. Climbed small hill with a couple of curves in it. Jeep kicked out of OD near the top, then BANG!

White smoke immediately blowing everywhere out the back and from under the hood.

Went down the hill, turned into a side road and backed out onto the highway. I thought I better get back on the other side of the hill while I still could. Went back up the hill, more or less coasted down the other side because the temp gauge was now into the red zone. Pulled into a state park and shut off the Jeep.

Tried to call my wife on the cell for about 30 minutes. Naturally, she had been in the shower and hadn't heard the cell or house phones.

Long story short, she came and got me, we continued on to Macs and I got the breakfast. Went back home, ate, got the Expedition and my ******-Um Strap, went back to the state park and towed it home, about 2.5 miles.

I thought it had blown a freeze plug or radiator hose. The freeze plugs in the block were all replaced with new brass ones about 150 miles ago because one started leaking pretty bad due to rust-out from the former owner just running water in the Jeep last year, maybe longer.

Looked up underneath; all 5 appeared to be in place as did all the hoses and clamps. I figured as fast as I lost coolant it had to be a large leak.

Got the water hose out, started putting water in the radiator. In just a short time, I saw and heard water running out underneath around the rear of the block and head near the bellhousing.

I just had a used head put on this thing about 1 1/2 weeks or 100 miles ago due to a cracked original head. I now thought either the head gasket had really blown a hole in it, the head was badly cracked externally, or the block cracked open. It was really hard to isolate where the leak was, but it had to be big. I had a real sinking feeling in my gut. "Just Empty Every Pocket". How true.

There was no water in the oil that I could see. Got to feeling around behind the engine. Finally found the problem. The freeze plug at the rear of my used head was completely gone. Only the big hole was there.

My question: since this is right up against the firewall, does the head have to come back out; or can the freeze plug be replaced while all is still in the vehicle?

Advice, please!

 

I'm sorry to say it but there's probably not enough room to get another one in there properly. I'd definitely give it a shot first but don't get your hopes up.

 

I do not know if they are still available or not, but you used to be able to get rubber expansion plugs from auto parts stores. You would need to get one to match the freeze plugs's size, of course, but you only need a wrench to install it.

Budd

 

I totally forgot about those. They work pretty well and would be perfect for this application. Good call

 

Yeah, I did an expandable block freeze plug some time ago on my '66 Mustang 289 after it blew one out on the freeway. It worked fine.

When I had the engine rebuilt we replaced all of them, of course.

 

that is your only option other than removing the head/engine.

 

If you have access to a lift, you can change that plug without pulling the head and redoing all the engine work you've done.

It's not that hard to pull the transmission... then put a screwjack under the front of the oil pan and roll the engine back on it's mounts.

You can get to that expansion plug really easily without the pesky transmission in the way.

 

That's very creative. Thanks!

 

Keep us informed on what you decide to do. I would have said the head had to come off but the prior posts sound very creative and I hope one works for you.

 

Too many moons ago to count, I worked for Arvin Ind. Inc. in Franklin IN as the forklift mechanic and the Continental flat head fours and sixes in the trucks (aka "mules") had a freeze plug between the block and the firewall and the choice was to strip the body work, & firewall, off to get at it or use an expansion plug.

I've always figured that Neccessity was the mother of Invention but it's daddy was Laziness.

My experience as a heavy equipment mechanic is where I draw a lot of my info, along with small engine repair and automotive repair.

Then some just comes off the top of my head like using the spring mounted whip from a magnet mounted base loaded CB antenna (base defective) to replace the bent AM/FM radio antenna on my XJ. It stays upright at 80 mph but will flex when hit by a tree / bush branch.

Budd

 

JMO but it seems instead of pulling drive-shafts, c-member, t-case, and tranny, it'd be faster to pull the engine. I'm probably wrong again though.

 

I would almost agree with you. They both are gonna take a couple hours of labor to get done but I would rather work standing up rather than laying on my back pulling a tranny and transfer case. I would not be that bad to pull the haed just label where all the plug ins go and you should be fine.

 

If you are at home with no lift, you are both right.

I would pull the transmission at my shop because I was a transmission R & R tech for four years. I can have the trans out, expansion plug installed, and the trans back in and test-driven in two hours.

And I wouldn't have to buy a head gasket set, or worry about breaking exhaust studs or cracking the exhaust manifold.

Different strokes...

 

yeah if you can use an expansion plug that is your best bet until you can do it right

 

Anybody got any experience with how long expansion plugs can last?