Oil Gallery Plug Removal

[AlfaLofa]

Any tips on how to shift these stubborn b******s would be most welcome.

Alternatively, I might just leave them be.

[pharriso]

Propane torch on the area around the plug?

[Lotus fan]

I decided to remove mine....but I wish I hadn't !!

Got 2 of them out easy enough but the 3rd !!!!!

Heat didn't work, managed to 'round' off the hex !!
Drilled it to use a reverse extractor on it........snapped the extractor !!!!

had to drill with 1.5mm drills around the periphery of the plug.....broke 5 drills in the process !!!!!

Can post pics of my toil if you like.

When I finally got the b*****d out the gallery was clear apart from the swarf I had created.

If you don't want frustration leave alone......
Or you might just get lucky !

Ian

[512BB]

I always remove them when I am rebuilding an engine. But if you are not going to strip the whole block down, including removing the jackshaft bearings, leave them in.

Reason. The only way I have found to remove them is to drill them out, with succesive size drills, starting with a 3mm drill, going right through the plug, which will drop some swarf into the gallery. So if you are not going to remove the crank and jackshaft and 3 bearings to thoroughly clean, leave them in.

Why remove the jackshaft bearings? Because the oil feed holes in the bearing do not always line up exactly with the matching holes in the block, leaving a bit of an overhang, which can trap a piece swarf, which will surely emerge when the engine is running.

Leslie

[AlfaLofa]

Ian & Leslie - thanks for your responses.

It just shows I shouldn't believe everything I read

"undo..... the three oil-gallery plugs using an Allen key"

What a nightmare.

I'll have one more attempt when I receive the appropriate 1/2" drive socket I've ordered - after which I'll give up.

As you say Ian, the gallery is probably ok anyway.

[rgh0]

I use heat on the surrounding block and a then freeze spray on the plug. 2 or 3 cycles of that normally will get them free. On a few occasions I have ended up rounding out the hex. I have filed up a shaft with a tapered drive fit into a rounded off hex and then worked again on removal using that. In the end I think I have had to drill the plug out on one occasion.

cheers
Rohan

[512BB]

Just remembered another method I have used in the past.

The plugs very often protrude up to 3mm from the block face. Carefully cut a slot across the plug, and then with your best tapping screwdriver, on the outside of the plug, tap away. Out she comes.....................sometimes.

They always give it up in the end !

I then run a tap in the threads to clean up, with care, as these are tapered threads. Don't forget to use a thread locker on replacing the new ones, you would not want one of those popping out.

Leslie

[alan]

i have a block and the rear o?l gallery plug has what appears to be a ballbearing pressed into the hole instead of a threaded plug
Alan B

[types26/36]

i have a block and the rear o?l gallery plug has what appears to be a ballbearing pressed into the hole instead of a threaded plug Alan B

That's normal, the earlier engines had a "welsh" type blanking plug (core plug) and the later engines had a ball type plug.

[alan]

many thanks Brian, i thought the block had been butchered. I feel much happier now
Alan b

[AlfaLofa]

Hi Brian - some questions about the "ball" plug fitted to later engines if I may.

What holds the ball in place?

What's the diameter of the ball?

Is a ball plug fitted to the oil gallery at the front face of the block as well as the rear?

[types26/36]

What holds the ball in place?

What's the diameter of the ball?

Is a ball plug fitted to the oil gallery at the front face of the block as well as the rear?

Steve,
I have never tried to remove the "ball" so can't answer how it held or it's diameter.
The front of the block has the normal screwed plug.
Have browse over this thread which has some pictures:
lotus-twincam-f39/711m-block-twin-cam-oil-passage-t24032.html

[StressCraxx]

We humble Formula Ford racers scour Craigslist for cheap core engines.
The ball is a press fit in the hole.

Two ways engine builders remove them:
Drill/grind out with carbide or abrasive bits.
Piece of welding rod welded to ball and pull out with a slide hammer.
That part of the galley around the ball can hold debris, so its usually removed.

Regards,
Dan

[AlfaLofa]

What lies behind the plug which screws into the arrowed hole on the right hand side of the engine adjacent to the engine mount??

(Picture courtesy of RD Enterprises)

[types26/36]

I believe that goes into the oil gallery, as I recall I remember seeing some Lotus Cortina's with the take off for the oil gauge from that hole.