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Welch plug needs changing 

 

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 Post subject: Welch plug needs changing
Posted: Sun Dec 26, 2004 12:56 pm 
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Tomorrow I have to change the front drivers side welch plug. :(

As I have never changed a welch plug before that I can recall, I was wondering if there are any pointers out thar?

Some questions follow.

I have searched the net and have been unable to find much assistance.

Cannot afford to take the motor out for a complete service so should I also change all of the plugs on the same side while I have the exhaust off and does anyone know the size ? (I have seen 38mm on this site but the statement was unsure.)

Are there any sites on the subject ??

What other parts should I need? (Welch plug(s), goo, exhaust gasket)

Can anyone sugest the correct goo?? (I will be going to Supercheep or Repco)

Oh, and the car is a 3.9 EA Fairmont Ghia :)

 

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Posted: Sun Dec 26, 2004 1:24 pm 
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I havent taken one out before, but my manual says you give it a hard knock on one side with a hammer and punch which should spin it. Then grab the edge and pull it out with a set of pliers.

I have put them in. Used some aircraft grade gasket maker. Clean all the old crap ouut of the plug hole, apply whatever sealent you are going to use, and then knock the new plug in using a hammer and a big socket.

I cant remember what size you need but just measure it or ask at any decent auto place and they will look it up for you. If you are going to replace all of them there is also one on the back of the block.

Oh, and just be a little careful, you dont want to know the plug into the block.

 

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Posted: Sun Dec 26, 2004 3:14 pm 
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It should take about 2hours to do the side ones on a EA six if you have the right tools and if you don't break any of the bolts.The plug size is 40mm I would replace the lot with brass. Stockstanded has mentioned most of what you need to do. Just remember to unplug the oxy senser in case you drop the exh manifold.

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Posted: Sun Dec 26, 2004 4:13 pm 
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yep yep always replace all not just one,like brake pads,,

 

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Posted: Sun Dec 26, 2004 4:50 pm 
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I have always wondered, what do these plugs do?

 

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Posted: Sun Dec 26, 2004 5:19 pm 
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comhelp wrote:
I have always wondered, what do these plugs do?


there the holes they make when they cast the block,,other wise it would all go bang

 

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 Post subject: Re: Welch plug needs changing
Posted: Thu Jan 13, 2005 8:07 pm 
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japa62 wrote:
I have searched the net and have been unable to find much assistance.

Cannot afford to take the motor out for a complete service so should I also change all of the plugs on the same side while I have the exhaust off and does anyone know the size ? (I have seen 38mm on this site but the statement was unsure.)

Are there any sites on the subject ??

What other parts should I need? (Welch plug(s), goo, exhaust gasket)

Can anyone sugest the correct goo?? (I will be going to Supercheep or Repco)

Oh, and the car is a 3.9 EA Fairmont Ghia :)



You can buy the Brass Welch Plugs at Super Cheap Auto and also Auto One.

You will also need some sealant such as STAG. Just smear a bit on the plugs edge before you knock them in.

To get the plugs out, just hit them in the side with a punch. They should swing out 90 degrees so you can grab them with some pliers. If they don't then you can try using a screwdriver on the edge to break the seal. Some people say just hit them in the middle with a screwdriver and hammer but mine still never came out until I broke the seal in the plugs edge.

The new brass plugs will go in easy as brass is softer than steel. I used what I had available and taht was a 38mm and 40mm Socket. I used the smaller 38mm in the inside of the plug first to start it off. Once I knew it was in there, I used the 40mm one to square it up.

I would advise getting new exhaust manifold bolts as mine snapped.

Total parts required:

4 Welch plugs (or you can get the set for later)
Stag sealant compound
Exhaust manifold gasket
O-Ring Gasket (If you take the manifold off the exhaust)

Total cost is the same as a case of Beer roughly

Hargest part is labour and the lack of hammer swing in the motor bay :)

Approx 2 hours work if all goes well
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Posted: Sat Jan 15, 2005 1:10 am 
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If you go down to your local Auto shop such as Bursons etc and ask for a full set of welsh plugs for your model. They should be able put a set together for you. Only buy brass welsh plugs. Always replace all water jacket welsh plugs. (you should be ok to leave the oil ones alone) remember there are welsh plugs in the rear of the block which you will need to remove the transmission to replace. Afterwards flush out cooling system and replace coolant.

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To get the plugs out, just hit them in the side with a punch. They should swing out 90 degrees so you can grab them with some pliers. If they don't then you can try using a screwdriver on the edge to break the seal. Some people say just hit them in the middle with a screwdriver and hammer but mine still never came out until I broke the seal in the plugs edge.


This is the correct way to do it. I used Stag on the welsh plug as a sealant, it also helps them go in.

 

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Posted: Sat Jan 15, 2005 1:48 am 
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Ummm... what is this about? Why would the plugs need replacing???? If they weren't plugged up what would be the problem???

 

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Posted: Sat Jan 15, 2005 7:53 am 
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Um i dont know about you but i dont really think a couple of 50-60mm holes in both sides of the blocks where the oil and water run ideal. I somehow think u MAY find it difficult to keep the levels up :mrgreen: :wink:

 

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 Post subject: Re: Welch plug needs changing
Posted: Sat Jan 15, 2005 2:52 pm 
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Nahaz wrote:
To get the plugs out, just hit them in the side with a punch. They should swing out 90 degrees so you can grab them with some pliers. If they don't then you can try using a screwdriver on the edge to break the seal. Some people say just hit them in the middle with a screwdriver and hammer but mine still never came out until I broke the seal in the plugs edge.


Sometimes they don't come out that easy..

I had to bash a hole in the centre of the plug, then use a tyre-iron (large levering bar), and had to pry it out.

--Striker.

 

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Posted: Sat Jan 15, 2005 2:59 pm 
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Lukieman wrote:
Ummm... what is this about? Why would the plugs need replacing???? If they weren't plugged up what would be the problem???


lol ... sometimes they rust out, start leaking...

 

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 Post subject: Re: Welch plug needs changing
Posted: Fri Feb 26, 2010 7:53 am 
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anyone have any pics so I know where to start ?
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 Post subject: Re: Welch plug needs changing
Posted: Fri Feb 26, 2010 8:16 am 
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you can also knock them into the waterjacket and pullthem out with a pair of multis if they wont spin.
also stag is not the best to use on welsh plugs as they are also there as a failsafe most top engine builders use aviation sealant no.3 as this never sets i.e it stays gooey. this is used because if the block ever freezes it will pop out a plug rather than go crack as a mate who wouldn't listen found out awhile ago (thankfully a holden red motor)

 

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i was just holding the lead and feeling the jolt it was giving me and seting the timeing from that

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 Post subject: Re: Welch plug needs changing
Posted: Sat Feb 27, 2010 10:22 pm 
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:evil: damn it stupid noobs reviving threade that are 5 years old :roll:

 

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i was just holding the lead and feeling the jolt it was giving me and seting the timeing from that

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