RE: [Chrysler300] G Freeze Plugs

["Bob Jasinski" <rpjasin@xxxxxxxxxxx>]

Richard,

This has come up before with the flat, domed shaped plugs, and is a somewhat
common problem.  I have had this type of expansion plug, installed even by
professionals, pop out shortly after the first engine start after a rebuild.
My solution may be viewed as a bit of extreme by some, but here is what I
do.

First off, find a replacement that is brass, not steel, that way it won't
rust out after time.  Clean the bore well, and mix up a small amount of JB
weld epoxy and coat the inner surface of the bore and the ledge where the
plug seats with it.  Seat the plug in the bore properly (dome side out)and
strike the center with a wide, flat tip punch to flatten the plug and widen
it out.  Wipe of any excess epoxy and let it set up.  You won't have a
problem with it again.

Bob J



-----Original Message-----
From: Richard Osborne [mailto:richard@xxxxxxxxxxxx]
Sent: Saturday, May 01, 2004 9:47 AM
To: chrysler300@xxxxxxxxxxxxxxx
Subject: [Chrysler300] G Freeze Plugs


Good Afternoon,

Yesterday afternoon we (Tom Miller and I) finally fired the G for the
first time. About 4 to 5 minutes into the cam break-in, it spewed a
freeze plug from the right side cylinder head.

After a few adult beverages and a cool down, I easily popped the
offending plug from the head. I was surprised to find a "flat" expansion
plug. By this I mean that it doesn't have a flange.

I just got back from Car Quest with a couple of similar style plugs. Am
I correct in understanding that the insertion method is to "ping" the
center of these to make it expand and seat propperly? After looking at
the previously installed vs. the uninstalled, this appears to be the
case (I paid the machine shop to do this about 3 years ago, so I wasn't
the original installer.).

Also, are these to be installed dry? It appearas as though the machine
shop used some sort of tacky yellow colored stuff on the plugs when
installed? Does this make sense. Of course, the machine shop was closed
by the time all of this happened.

Please advise if the concave shaped plugs are meant to be installed by
hitting in the center as to expand the plug and if you recommend
installing these dry or with some sort of sealer?

I may try to put a temporary rubber plug in just to see how many others
will pop out during operation. I'm not too sure I can get it in. We'll
see.

Best regards,

Richard Osborne





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