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Old 04-01-2015, 09:50 PM   #1 (permalink)
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Default Hole in freeze plug 05 Forenza. Need size or part number.

Looks like it's time for me to ask for help this, uh, time

Freeze plug directly behind the exhaust manifold suddenly developed a 5mm hole in it. A royal pain in the buttocks to remove so I managed to mangle it quite a bit. I can't find a direct replacement on the web via car model or it's equivalents.
I don't have a caliper or micrometer so I don't know the exact size, plus I had to grind a thin slot through the rim so the darn thing would come out.
The best measurement I could take using a crappy metal ruler was ~34mm wide and ~12mm deep.
The closest equivalent I've found is Dorman 555-104-B which measures 34.3mm*0.497.
Does anyone know what the correct replacement size or part number I need?
If worse comes to worst, I'll have someone weld a plate over the hole or something (if that's even possible). It'll never freeze out here anyways...
Help? Anyone? Thanks in advance.
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Old 04-02-2015, 05:08 AM   #2 (permalink)
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Not sure about the size- but ideas for future reference.

The plug needs to hold pressure, the cooling system is under about 15 psi

If you can't get the plug out, try pushing it in. if it falls inside, not a big deal.

john
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Old 04-02-2015, 09:17 AM   #3 (permalink)
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Thanks Waiter21.
The method I used (rather unsuccessfully) was the way I saw it on nearly all the freeze plug removal videos I watched.
I used a short brass drift at about 10mm diameter and hit the inside edge farthest away from the hole trying to force that side inwards.
That should have had the desired effect of forcing the opposite edge of the plug outwards where it could be extracted using channel lock pliers.
It would not even budge the lip at all, only deform the flat surface of the plug inwards.
I took care to not hit the plug always in the same place, but eventually it broke through the plug until there was just the rim still stuck in the hole.
I tried to pry the mangled backing out with the channel locks, only succeeding in ripping out pieces of freeze plug (which is pretty darn thick and tough steel).
I then took my Dremel with a carbide cutting tip and ground a thin slot in the rim so as to weaken its death grip on the hole.
Once the rim was weakened, a few taps with a hammer and flathead screwdriver finally made (what was left of) the plug rotate and able to be extracted as normal.

If I had to do it again I would use a wider flattened and rounded brass punch and hit it dead on the inner edge of the plug at either the right or left side. I was hitting the bottom left inner edge (furthest away from the hole) at an angle (to avoid hitting the outer cylinder wall).
There was very little space behind the plug, so there is no danger of having it fall in (the rim is simply too wide).
There is more room on the sides for the plug to rotate, so I'd avoid hitting the top or bottom.
I'd hit it straight inwards and not at an angle as the wide rim fought me all the way. Don't take a sledgehammer to it, and careful with using sharp or steel implements; you don't want to put a hole in the cylinder wall. That would kinda suck.

I really hope this helps someone else, somehow.

Going to the auto parts store today with what's left of the plug to see if they know what size it should be, but if anyone knows, put it here for our future reference. Thanks!
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Old 04-02-2015, 01:43 PM   #4 (permalink)
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Guy at the auto parts store measured it and handed me...
Dorman 565-104
which measures 34.3mm*0.497 just like the one I suspected.
They were $1.58 apiece and are made of nice thick brass.
Used the Dremel with a flap sander on the engine block hole to clean up any corrosion.
Knocked it in using a hammer on a socket a few mm smaller than the inside of the plug until it was flush with the bevel. It was a nice tight fit, it took quite a bit of effort to drive it in nice and square.
Job done. Hope it helps someone.
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Old 04-02-2015, 02:24 PM   #5 (permalink)
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Better late than never
Is number 7 the plug in question ?

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Old 04-02-2015, 03:05 PM   #6 (permalink)
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Ha! I knew someone would find the OEM part eventually, lol.
Thanks Dudleydo
The part is labeled 2 on the diagram.
On the chart it is labeled (2-1): 11239-84Z00 *CAP CYL BLOCK
Part (2-2) is the oversize, which they do list (OS: 36mm)
Too bad they don't mention the stock size and I can't find any info on that part number.
Well, 34.3mm worked in mine. Tested just now and thankfully, no leaks (knock on wood).
Thanks again to both of you!
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