04-02-2015, 09:17 AM
Join Date: Jan 2011
Location: PR, USA
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!