« Reply #1 on: June 11, 2009, 08:46:46 PM »
To change a press-in freeze plug:
Drain coolant, including engine block drain plug (left rear side of block) - if coolant is clean, you can reuse
Use a hammer and chisel or sharp punch to dislodge and remove leaking plug
Clean out the hole (look for any trash or imperfections that could be causing a leak)
Lightly coat the outer edge of the new freeze plug with RTV (optional)
Use a socket or other round object that is slightly smaller than ID of the freeze plug to drive it straight into the hole
Stop driving when the outer lip of the freeze plug is past the edge of the block and the plug bottoms out (look at the other plugs for reference)
If you used RTV, let it dry
Close block drain and radiator petcock
Refill coolant
Leak test
Logged
95 YJ, 31 BFG ATs, 4.0 TB & spacer, Banks header, DynoMax CAT back, 19# inj, AEM CAI, 20 gal mod, Optima yellow
98 TJ, 35 BFG Krawlers, 4.0 liter, ax15, atlas 5:1, armor, Super 88 (under construction)
96 XJ Cheep Cherokee, 33s, 4.0 liter, AW4, future project
89 Waggy, 360 V8 727 dana 44s, it runs