[EDNY]

Posted this on a couple LT1/LS1 forums...let me ask it here...maybe an old schooler might be able to help.

Any suggestions for removing the steel square hole pipe thread plug from a 95 LT1 aluminum head?

Have the engine up and running in a 37 Chevy and need to leave the OEM temp sender on the drivers side (for the PCM)... would like to install an aftermarket temp sender in the plug hole on the passenger side head for the dash temp gauge.

Torqued a little with a 5/16" square head socket via a 3/8" drive ratchet...but just get that "feeling" that I need to back off before something breaks

Do have coolant in the block...any suggestions?

Thanks

[sammons]

Ed I haven't tried it on an aluminum head, but I had an old Vette aluminum intake with the same problem. I've broke the aluminum before trying to get them out. I put a fine weld tip on the ocy/acet set up and just concentrated a fine point flame on the square head, heated real good, thru some ice water on it. I then put the end wrench on and give it a firm tap with a hammer (to tight), then rapped it to lose and it came right out. I've gotten several out that way with out damage to the intake.

[EDNY]

Sammons


I tried the torch method briefly...just a bit nervous &  the car is about ready for the road, don't want any setbacks.

Have a snap-on 5/16" square socket in 3/8" drive..been thinking about getting a 1/2" drive impact socket and give it a light impact gun try. Maybe with engine warmed up since the aluminum will expand before the steel plug.

ebay link:

http://www.ebay.com/itm/Grey-Pneumatic-2010PP-1-2-Drive-x-5-16-Square-Male-Pipe-Plug-Socket-/190740964619?pt=LH_DefaultDomain_0&hash=item2c690c250b

[sixball]

I do the heating, cooling, tapping several times before I put any serious torque on it. It might be best to lower the coolant level so you don't have to heat it too and so nothing comes out but the plug.

[themoose]

Ed...I've used the impact method that you described many times and was always successful. Works the same as if you have an overtightened or frozen lug nut and try to loosen it with a breaker bar. Seems like you can pull on the bar with all your might and nothing happens but with the impact method it spins right off.

[EDNY]

Thanks Moose (et al)

Looking at my Snap On socket it's actually 8mm...so I'll check with a couple contacts and try to locate a true 5/16".  Also feel confident working with the impact.  Worse come to worse I have an extra set of aluminum heads

[ghost28]

I can't help you, but I know it's hard because I tried and tried to get a fitting out of a aluminum manifold. I never did get it out.

[62131]

I think drilling it would be the best option and using a little TLC slow and easy.

[EDNY]

I should probably call my local machine shop..they do SBC heads all of the time.  Will keep you posted...

[EDNY]

Update: Borrowed a 5/16" socket and used a 1/2" drive...no more wrench flexing and it came right out

Thanks...

[ghost28]

That's great news.