I have a 02 2500 4/4 HO 6spd with a expansion plug on the back right corner of the head leaking. This bugger is about the diameter of a #2 pencil. Does anyone know how to replace it without removing the head? I can't figure why it started leaking, the truck only has 108K miles and the coolant changed regularly. Thanks in advance for any help!

 

Passenger side?

Tough spot to work in. Thats an odd spot for a leak, I'll check mine out today and see if I can locate it and think of something.

 

Thanks, Sixslug, yes, it's on the pass. side. The head is flat in the back but has a 45 degree bevel on the corner before it goes up the exhaust manifold side. This plug is in the middle of that bevel. I got the replacement plug, but trying to figure how to put it in.

 

after you get the old one out or drive it all the way in, tap the hole 1/8" npt and screw in a brass 1/8 pipe plug.

 

THAT is a very good idea! Getting the tap started is going to be a challenge but a lot better than trying to hammer in a plug straight. I would try to get the old one out as opposed to driving it in, it is small enough that it could end up causing issues with the pump. Drive, drill or punch a small hole in the old one and thread in a screw and grab it with a pair of side cutters and you should be able to lever it out.

Rick

 

I looked and think the above 2 posts are what I would do in a similar situation.

 

Thanks, guys. That sounds like a plan! I'll let you know how it turns out!

 

drain motor,take heat gun,dry plug,fill with jb weld