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Leaking 4.0 Freeze plug replacement

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Weeeee

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Discussion starter · #1 ·
So I have had a slow leak on my TJ for about a month and couldn't find it until today. I rented a pressure tester and was able to finally see the leak, it is slowly leaking from the freeze plug located near the front of the block by the AC compressor.

To replace it I am going to have to pull the intake and exhaust manifolds and probably the power steering pump. These are my best guesses since I have never pulled these on a jeep.

I have some questions for those who may have done this.

1. Any online guides available to help me?
2. What else should I replace since I will have all of this torn apart? Intake and exhaust gaskets, injector o-rings etc?
3. What kind of freeze plugs should i get(I am planning on replacing all the ones on the block that I can easily get too since I will have this torn apart)?
4. Will I need a special tool to put new ones in(never did a freeze plug)?
 
#3 ·
Well if it were me, I would only replace the leaking one, the reason being "if it ain't broke, don't fix it" you may have a sealing problem with the replacements, unless there is signs of seeping/leaking on others replace them too.

As far a tools, I would use a sharp punch, knock a hole in it, grab with a needle nose then pull, bend, warp, twist, what ever to get it out. If you don't, and it falls down unreachable, don't worry about it and go on with installing a new one.

Clean hole well, some may want to put gasket sealer on new plug not really needed though. Center and align/square plug in hole and with a socket size that just fits inside the lip of the plug tap in to where it is just below the block surface.

Hope this helps some, , ,
 
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#4 ·
I have a pin hole leak in the 2nd (from front) freeze plug. Has anyone replaced this plug without removing the air intake? Looks like the engine mount/heat shield could come off and provide access to the plug?
 
Discussion starter · #5 ·
Donbo said:
I have a pin hole leak in the 2nd (from front) freeze plug. Has anyone replaced this plug without removing the air intake? Looks like the engine mount/heat shield could come off and provide access to the plug?
Click to expand...
I just finished replacing all 5 of them. I doubt you could get to the first two without removing the intake and exhaust manifolds. It's a royal PITA.
 
#7 ·
Has anyone else tried to remove the driver side engine mount instead of the intake/exhaust manifolds to replace the 2nd freeze plug from front on a 4.0 in a TJ? Really not looking forward to removing manifolds...

Thanks,
RMJ
 
Discussion starter · #8 ·
Ryno_WJ said:
Has anyone else tried to remove the driver side engine mount instead of the intake/exhaust manifolds to replace the 2nd freeze plug from front on a 4.0 in a TJ? Really not looking forward to removing manifolds...

Thanks,
RMJ
Click to expand...
Not sure if there will be enough clearance to take the 2nd one out with the manifolds in.

When I put it back together I might have a better idea if it's possible.

Image
 
#18 ·
Weeeee said:
It's an engine block thats 10 years old in Chicago. Doubt there is an engine block up here that doesn't have rust on it. The block is also just dirty from clay and mud, but it's also wet from antifreeze and liquid wrench in the pic.
Click to expand...
and it's also showing raw zinc steel freeze plugs. just waiting for winter splash to corrode them back out. Spend $5.00 and spray bomb them.
Would you like to see pics of $100,000 CAT 3406's that have spent 10 years in a salt water environment, painted?
 
Discussion starter · #19 ·
never monday said:
and it's also showing raw zinc steel freeze plugs. just waiting for winter splash to corrode them back out. Spend $5.00 and spray bomb them.
Would you like to see pics of $100,000 CAT 3406's that have spent 10 years in a salt water environment, painted?
Click to expand...
Actually the freeze plugs are brass so they don't rust, if I had used the steel one's I probably would have hit them with some high heat paint like your suggesting.
 
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