'94 D90 cooling problem-plastic cap broken - Defender Source
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  #1  
Old April 27th, 2008, 11:45 PM
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Keith Kuboske
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Unhappy '94 D90 cooling problem-plastic cap broken

Was going to check burp cooling system via taking off the plastic plug on the heater side, plastic plug on the radiator and the overfill cap. The heater side plug must have never been removed and stripped out the plastic threads the first couple of turns. After fighting with it for an hour, took a hack saw blade and cut off the top of the plastic cap and cored out the middle, got everythin out except the outside ring of the plastic that will not fit through the opening, even if lighned up and screwed. (whoever thought to use plastic on metal was screwed in the head) . Anyways, can not get this piece out, It will not go far down the tube as it is larger than the bore of the hole. This would had to happen to my wifes pristine D-90 instead of my D-90 work in progress.
Anyone have any ideas on how to get this out? I would hate to have to leave it like this. Thought about taking a sodering iron and trying to melt one side through so i could bend it out. Would have to tie some sort of line to it so it would not slip. I am open to suggestions....
Also does anyone know the NAPA part number to replace the plastic bolt with one that is metal or aluminum (not sure of the compasition of metal on radiator and heater side.)

Thanks'
K Kuboske
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  #2  
Old April 28th, 2008, 07:08 AM
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Joe Barefoot
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Maybe try to "saw" it in half with a small grinder on a dremmel tool, from the inside out to the upright tube. Expedition Exchange has some nice brass replacements, I have one for my coolant tower plug and for the radiator plug.
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Old April 28th, 2008, 08:35 AM
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Keith Kuboske
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Thanks Joe.
Did not want to wait to get from e.e. As vehicle is disabled thought napa may have a brass plug that would work in stock, but maybe only option.
thought by melting it may keep shards out system if kept from dripping
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  #4  
Old April 28th, 2008, 02:13 PM
snurp
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Keith Kuboske
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I went ahead and ordered the brass caps from EE...did not want to risk rigging something up from NAPA as not sure what the thread pattern was (probally British pipe thread instead of NPT). Still need to find out some more ideas on how to get out the reminder of the plastic nut out. (threaded portion still intact and in hole).
Thanks for any and all info. and ideas,
K Kuboske
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  #5  
Old April 28th, 2008, 03:08 PM
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Brian B
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I recently had the exact same thing happen. If you haven't already removed the entire metal heater pipe assembly from the truck, you'll need to in order to remove all the shavings from what's left of the plastic cap. I cup the cap off and drilled out the core as you did. I then took a hacksaw blade and gently cut the bored out core in two places 180 degrees apart almost to the metal threads. I had a sight bit of of the core left above the top of the pipe, so I put it in a vise and used pressure to crack what was left of the core along the hacksaw cuts. Then I pulled the pieces out with needle nose pliers. The threads of the heater pipe still had the remains of the plastic core threading, so I used a Dremel with a wire brush to clean up the threads. That was the longest coolant flush ever.
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  #6  
Old April 29th, 2008, 02:36 PM
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Joe Barefoot
'94 D90, '07 D110, '08 LR2, '09 D90
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Is there a large "easy out" drill bit made? The kind of thing you use to get out rusted/stripped bolts and screws? It is essentially a cone shaped bit with reverse threads.
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