A few months ago I took care the ground straps. Posted it on the forum.
update- finished. Attached writeup with pictures
Freeze Plug Replacement on a 1995 ford Explorer 4.0L OHV 4X4 engine in the Vehicle-
This is from my experience and my opinion.
Choice of Freeze Plug to use. Steel, Brass and Rubber. Standard Size for the side Plug are 1 ½”.
Steel is the factory standard, with a sealant. The PRO- if you drop the freeze plug in the block you can grab it with a magnetic, CON- it will rust out in 25 years.
Brass- non-magnetic, if you drop the freeze plug in the block, SOL, unless you can grab it with a pickup tool.
Rubber- short life span, Fast and simple.
You need to uses an installation tool. See pictures 1, of what I used.
I used a caught pan for the coolant. I figure there was a hole in the plug , coolant was leaking out and couldn’t be a lot coolant left in the block. When the plug was remove about ¾ of a gallon came out. Picture 3
A lot of people use a socket with an extension. That only works if the block is out of the vehicle or you have are straight on installation.
The problem I had if the plug is not square to the face (opening) its does not square itself up during the installation. I thought the plug would square up because of the outside shoulder of the tool, but it does not.
First I removed the original steel plug with my air hammer( picture 2) with a long shank. It made it easy to knock the plug loose. It drop into the block, I grab it with a vise grip. Took a long pry bar and bent the edge and it came right thru the opening.
Second Plug (brass) was not square, so I remove it. I drill a small hole in the plug, Put a soft wire thru the drill hole to whole the plug, while I bent the edge and pull it right out. A self-tapping screw and the socket method did not work for me.
Third Plug Brass. Now I used the installation tools. The 4603 made it easy to get in there and install the plug. When I notice it was not square I switch over to the impact arm from Tool 4604 and used the air hammer so I did not have to swing a hammer. See Picture.
Fourth Plug brass I drilled a small hole in the plug. so I could insert a small bend wire in the hole to caught it as I knock it free.
Sealant – Everyone uses something different. Some use Red RTV, Some use Black RTV, I first used Form A gasket. Then I switched to Permatex Indian Head gasket shellac. This is what I use on the coolant hose. It worked the best for me. They make a core plug sealant, but very expensive. Locktite makes a sealant same as the other brand. which is the red thread lock sealant; same spec.
Pre cleaning the core plug opening. I used Green Scotch brite pad. Worked Fine. I also used a long neck die grinder with a sanding drum on it. The core was in good condition.
Tips: I set the new plug in by hand, and try to keep it square to the hole. To straighten it out I used ½” drive extension about 24“ long. I Tap the shoulder of the plug to square it up. What I notice, was the core plug installation tool fit the plug just right before installing the plug in the block, but did not work if the plug was installed, because the wall of the plug push inward when installing. So I used smaller plug socket. See finish picture.
