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Durango 5.9 freeze plug change - DIY? #1076030
09/16/11 06:21 PM
09/16/11 06:21 PM
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Vancouver, WA
MoparMarq Offline OP
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Freeze plug on front driver's side of block weeping.
Never changed one before - either in or out of the car. Access looks best from the bottom, as headers and PS pump are in the way from above. I'd rather not go the StopLeak route, if possible.

Got plenty of tools, just not sure if I should be doing it. Any ideas/thoughts for a freeze plug noob?

Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076031
09/16/11 10:22 PM
09/16/11 10:22 PM
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Maryland
GO_Fish Offline
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Thank GOD your leak is on the front. Very doable for shade tree mechanics. Use a big straight blade screwdriver or chisel and punch one edge of the leaky plug. It will start to pivot, and then you can grab the opposite side of the plug with some Channel Locks, give it a yank, and the hard part is done. Get your new plug (I like brass), and find a socket that fits inside the plug. Put some Permatex No.1 (hardening) around the edge of the new plug, put the socket in the new plug and tap the socket with a hammer until the new plug is about 1/8" below the face of the block. Let it dry and refill your coolant and you are done!


Scott B. "I'm a self-made man... I started with nothing, and I still have most of it!" 68 360 rusty B'cuda 'vert (GO Fish)13.59@ 98.72 mph 69 340 GTS stock 14.18@ 95.60 mph 01 5.9L Ram 1500 Quad Cab 4x4 01 3.5L 300M 16.23@ 86.97 mph
Re: Durango 5.9 freeze plug change - DIY? [Re: GO_Fish] #1076032
09/16/11 11:50 PM
09/16/11 11:50 PM
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Vancouver, WA
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I took a look at it this evening. If I remove the front left tire and wheel well liner, access should be easy. Guess I'm going to Napa tomorrow for a brass plug, Permatex, and maybe a cooling system pressure test set (can't really have enough tools, can ya? ). Thanks for the help.

Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076033
09/17/11 12:25 AM
09/17/11 12:25 AM
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Tustin, CA
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pishta Offline
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Rubber expansion plug. Works well when you cant get a driver or hammer in there.

6829737-unnamed.jpg (616 downloads)

12 Grand Caravan
06 T&C
02 T&C
96 Breeze
65 Barracuda "S"
Re: Durango 5.9 freeze plug change - DIY? [Re: pishta] #1076034
09/17/11 09:02 AM
09/17/11 09:02 AM
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Niles , Ohio
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therocks Offline
oh wait.but hey.lets see.oh yeah.
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Lots of people say the rubbers are junk.I had them in one block for at least 10 years.I started using the solid ones that tighten in like the rubbers.A lot of the newer cars you cant get to the plugs unless you do a ton of RR work.Most people didnt want to pay say 200 bucks for that.The solids I installed were in for years and never had any problems.Just clean the hole real good.I use a piece of fine sand paper then brake clean.Rocky


Chrysler Firepower
Re: Durango 5.9 freeze plug change - DIY? [Re: therocks] #1076035
09/18/11 02:45 AM
09/18/11 02:45 AM
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Vancouver, WA
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Picked up a freeze plug kit today. Pressure tester borrowed from A-zone. Found leak. Thought it was on the driver's side. Nope. Just coolant migrating around the oil pan rail from the passenger's side. Coming from aft freeze plug on passenger side - right in front of oil filter. Luckily reached it through the gap between the frame and fender liner. Factory block heater in lieu of freeze plug. Got it out okay. Crappy O-ring. Tried test fitting the new freeze plug in the hole with a socket and various extensions. No go. Can't get enough swing on a hammer to pound the freeze plug to start - even with the oil filter removed. Want to avoid the rubber plug method. Gonna try making a tool tomorrow from a length of household plumbing pipe (my erstwhile cheater bar) with the end cutoff at an angle to fit flush on the plug and hammer on the end that extends below the frame just past the LCA. Had one today, but the angle wasn't quite right.

FWIW, no sediment in the jacket as far as I could feel and cylinder walls looked nice and clean even though the coolant was probably the factory fill.

Last edited by MoparMarq; 09/18/11 02:48 AM.
Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076036
09/18/11 07:24 AM
09/18/11 07:24 AM
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Posts: 6,167
Maryland
GO_Fish Offline
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I don't know Durangos, but is there a plastic fender liner inside the wheel well that you can remove? Maybe with the wheel taken off and the liner removed you can get a better shot?


Scott B. "I'm a self-made man... I started with nothing, and I still have most of it!" 68 360 rusty B'cuda 'vert (GO Fish)13.59@ 98.72 mph 69 340 GTS stock 14.18@ 95.60 mph 01 5.9L Ram 1500 Quad Cab 4x4 01 3.5L 300M 16.23@ 86.97 mph
Re: Durango 5.9 freeze plug change - DIY? [Re: GO_Fish] #1076037
09/18/11 10:26 AM
09/18/11 10:26 AM
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Niles , Ohio
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therocks Offline
oh wait.but hey.lets see.oh yeah.
therocks  Offline
oh wait.but hey.lets see.oh yeah.
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If you cant get it try the solid expandable plugs.The are like the rubbers but totally solid.Just install and tighten down the nut.Ive used them a lot at work.Simple and easy and a few are still working even after 4 or 5 years.I have the tool to install plugs and on a lot it still dosent work as they are buried.Rocky


Chrysler Firepower
Re: Durango 5.9 freeze plug change - DIY? [Re: therocks] #1076038
09/18/11 05:46 PM
09/18/11 05:46 PM
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Central TX
roe Offline
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I used the rubber exapandable one pictured above and it worked just fine without failing. I cleaned the hole really good, and hit it with some sand paper. I also took it as a chance to flush the coolant passages. Never had a problem with the rubber one.



1971 Plymouth Satellite
408/904 8 3/4 3.23 SG
Re: Durango 5.9 freeze plug change - DIY? [Re: roe] #1076039
09/18/11 07:54 PM
09/18/11 07:54 PM
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Maryland
GO_Fish Offline
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The rubber one should be okay in normal use. If you rev the engine high racing or towing, you run the risk of popping it out and dumping coolant on the ground in front of the rear wheels...

At normal rpm's it should be fine, I'd put a wrench on it once in a while to make sure it is still snug.


Scott B. "I'm a self-made man... I started with nothing, and I still have most of it!" 68 360 rusty B'cuda 'vert (GO Fish)13.59@ 98.72 mph 69 340 GTS stock 14.18@ 95.60 mph 01 5.9L Ram 1500 Quad Cab 4x4 01 3.5L 300M 16.23@ 86.97 mph
Re: Durango 5.9 freeze plug change - DIY? [Re: GO_Fish] #1076040
09/18/11 08:23 PM
09/18/11 08:23 PM
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Vancouver, WA
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Briefly thought about the hard rubber type, but my wife wouldn't know if the car was overheating if the Lord himself came down and told her. Plus, with my little helpers, ages 7 and 5 in the car, she'd be none too pleased to be stuck on the side of the road.

Pic of the factory block heater removed.
Hole is wire brushed and sanded...

6831990-Freeze_plug_1.jpg (6541 downloads)
Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076041
09/18/11 08:25 PM
09/18/11 08:25 PM
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Vancouver, WA
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The tool I had to make to get the driver to sit flat on the new plug because it comes up from the below the frame rail through a gap in the LCA.

6831994-Freeze_plug_4.jpg (765 downloads)
Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076042
09/18/11 08:26 PM
09/18/11 08:26 PM
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chicagoland,usa
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buildanother Offline
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Looks nice and accessible. I would have pulled the engine and replaced all, but I am used to that.

Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076043
09/18/11 08:26 PM
09/18/11 08:26 PM
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Vancouver, WA
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Convenient that it fit the inside of the plug with a little room to spare...

6831999-Freeze_plug_3.jpg (784 downloads)
Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076044
09/18/11 08:32 PM
09/18/11 08:32 PM
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Vancouver, WA
MoparMarq Offline OP
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Plug and flush with block. The Napa plug kit came with a raft of plugs. The 1-3/8 plugs were all a bit deeper flange than the factory ones in the block. They made the factory plugs look chintzy by comparison. Use RTV silicone black as a sealant. Letting it cure for the 24 hours that the directions say to wait. Fill, flush, and fill tomorrow and pressure test with the tester from A-zone...

I'm sure anyone else would've had this done in less than a few hours. But my girls were in and out of the garage all day yesterday on their scooters and bikes, and of course leaving them in the way when they swap rides. They're greeat little helpers; they turn any 1 hour job into a 4 hour job...

6832006-Freeze_plug_5.jpg (8141 downloads)
Re: Durango 5.9 freeze plug change - DIY? [Re: buildanother] #1076045
09/18/11 08:38 PM
09/18/11 08:38 PM
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Vancouver, WA
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Quote:

Looks nice and accessible. I would have pulled the engine and replaced all, but I am used to that.




By comparison to the others, it actually was pretty accessible, just a funky angle on the makeshift driver. I hope I never have to do the others. Looks like after the flush and fill, I'll be picking up a sacrificial zinc anode to mitigate any possible corrosion on the rest of the system.

Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076046
09/18/11 08:39 PM
09/18/11 08:39 PM
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pishta Offline
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Its going to go in at an angle so dont go crazy and use the 5 lb'er on it unless you know you are seated square. That is a good shot at it, the ones under the exhaust are a bear. Looks like that tool can be rotated a little to compensate for any cocking of the plug, gotta good chance!


12 Grand Caravan
06 T&C
02 T&C
96 Breeze
65 Barracuda "S"
Re: Durango 5.9 freeze plug change - DIY? [Re: pishta] #1076047
09/18/11 08:59 PM
09/18/11 08:59 PM
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Vancouver, WA
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Quote:

Its going to go in at an angle so dont go crazy and use the 5 lb'er on it unless you know you are seated square. That is a good shot at it, the ones under the exhaust are a bear. Looks like that tool can be rotated a little to compensate for any cocking of the plug, gotta good chance!




I did use a 5 lb'er on it, but checked it multiple times as I was driving it in. Fortunately the TLAR ("that looks about right") method I used to cut the pipe was almost dead on, and I was able to adjust the position and rotation of the pipe to drive the plug near perfect square all the way in. It may be off from square by several .001s, but having the engine out wouldn't have improved my eye any.

We'll see tomorrow.

BTW, the Durango factory cap is 21 lbs. Anybody using a 16 lb. cap on their 5.9? Ours doesn't see any 100 degree temps here - 21 lbs. seems like overkill...

Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076048
09/18/11 09:07 PM
09/18/11 09:07 PM
Joined: Jan 2003
Posts: 21,079
Niles , Ohio
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therocks Offline
oh wait.but hey.lets see.oh yeah.
therocks  Offline
oh wait.but hey.lets see.oh yeah.
T

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Posts: 21,079
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16 pound on my 99 since I got it in 2000.Never any problems.Rocky


Chrysler Firepower
Re: Durango 5.9 freeze plug change - DIY? [Re: MoparMarq] #1076049
09/19/11 07:12 AM
09/19/11 07:12 AM
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Central TX
roe Offline
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Quote:

Quote:

Looks nice and accessible. I would have pulled the engine and replaced all, but I am used to that.




By comparison to the others, it actually was pretty accessible, just a funky angle on the makeshift driver. I hope I never have to do the others. Looks like after the flush and fill, I'll be picking up a sacrificial zinc anode to mitigate any possible corrosion on the rest of the system.





Unfortunately when one is going, there are usually a few more right behind it. After I replaced my leaky one, I started poking around at the others and there were 3 more that were so paper thing that a screwdriver poked right through it without any real force exerted. Ended up replacing all of those as well. Definitely worth a look while you're down there.

roe



1971 Plymouth Satellite
408/904 8 3/4 3.23 SG
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