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Old 11-10-2012, 05:46 PM   #1
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454 oil galley plug problem

I've been slowly working towards installing the ancillary parts on my fresh 454 rebuild and ran into a problem. The engine builder installed a plug in the oil galley where the oil pressure sender goes. I tried removing it today and it was so tight the hex opening in the plug rounded out. Yes, I had full depth with the allen wrench when I was doing this I then tried an easy out (easy my *ss) and it bit but wouldn't loosen the plug. It then rounded out the plug even more. I'm not sure what he used for sealant when he installed the plug but it's not coming out.

At this point I'm not sure what to do. Are there any other oil galley plugs that can be used for oil pressure sensors? If so where are they?

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Brad
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Old 11-10-2012, 05:56 PM   #2
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holy crap, have you thought about welding the wrench to it?
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Old 11-10-2012, 06:03 PM   #3
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holy crap, have you thought about welding the wrench to it?
If I can find no other alternative I might give that a shot. I've had success in the past removing broken bolts that way but needless to say I'm not thrilled about the idea of welding something to my freshly built engine

Brad
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Old 11-10-2012, 06:46 PM   #4
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Is that the only place you can tap into the oil gallery? If you can't find another place to put the sender you are going to have to drill out the old plug. The problem is that there is a real big chance of messing up the threads. You could take the engine back to where you got it and let them deal with it.

Perry
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Old 11-10-2012, 07:03 PM   #5
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The plug might have been installed with red thread locking compound, which will not break loose with hand tools. Can you contact the engine builder and see what he recommends? Welding might be an answer. If someone who has good welding skills adds some rod or wire (it could be mig, tig or stick in my opinion) a little at a time so as to not heat the plug too tight and crack the block; then once the hole is filled and the weld sticks out proud by about 1/2" you might be able to get some vice grips on the weld and back the plug out. The heat of the weld may break loose the thread locking compound if that is the problem.

I agree with Perry. If the engine builder is a local person, I'd try to get him to come over to your place and see if he will help you (at no charge). I'm sure that you'll get this worked out, but it sure is frustrating!

Steve
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Old 11-18-2012, 08:24 AM   #6
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Red loctite can be released with heat
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Old 11-18-2012, 12:09 PM   #7
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Quote:
Originally Posted by perryg114 View Post
Is that the only place you can tap into the oil gallery? If you can't find another place to put the sender you are going to have to drill out the old plug. The problem is that there is a real big chance of messing up the threads. You could take the engine back to where you got it and let them deal with it.

Perry
On the 454, I believe there should be a plug at the oil filter mount that goes into the oil galley, as well as a plug next to where the distributor mounts - worth checking.
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Old 11-20-2012, 11:22 AM   #8
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Red loctite can be released with heat
Using heat on a brand new engine scares me! I think I would rather leave that plug in place and pick another place to put the oil pressure sender.
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Old 11-20-2012, 11:31 AM   #9
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On the 454, I believe there should be a plug at the oil filter mount that goes into the oil galley, as well as a plug next to where the distributor mounts - worth checking.
I'm assuming the oil pressure port by the filter housing would be the small square plug to the left of the large square plug above the oil filter mount. If that's the case then I'll try and remove that plug this weekend.

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Thanks,

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Old 11-20-2012, 01:13 PM   #10
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Using heat on a brand new engine scares me! I think I would rather leave that plug in place and pick another place to put the oil pressure sender.
It doesn't require that much heat to release red loctite
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Old 11-20-2012, 04:12 PM   #11
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It has been forever since I have seen an oil flow diagram for a 454, let alone worked one one, but I believe that the port at the filter will give you basically pump output pressure, whereas the one at the front of the engine gives pressure after all the leak off after (at least ) the mains are lubed.

For me, I'd rather know the "low side" pressure. That lets you know the relative health of the bearings AND the pump. Mounting at the filter could give a "false high", I think...IIRC.

Use some heat and get the front plug out is my advice.
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Old 11-21-2012, 07:15 PM   #12
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It doesn't require that much heat to release red loctite
If I use heat what I'm thinking is to use my smallest welding tip and heat the inside of the hex (or what used to be a hex, now its round) with the tip of the blue flame. I'll start out just touching it momentarily and see what that does.

Still scares the crap out of me

Brad
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Old 11-21-2012, 07:16 PM   #13
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Originally Posted by dznf0g View Post
It has been forever since I have seen an oil flow diagram for a 454, let alone worked one one, but I believe that the port at the filter will give you basically pump output pressure, whereas the one at the front of the engine gives pressure after all the leak off after (at least ) the mains are lubed.

For me, I'd rather know the "low side" pressure. That lets you know the relative health of the bearings AND the pump. Mounting at the filter could give a "false high", I think...IIRC.

Use some heat and get the front plug out is my advice.
I agree, I'd rather know the pressure after it's been through the bearings. As I stated in my post above I'm going to go ahead and try some heat.

I'm hoping to give it a try this weekend.

Thanks,

Brad
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Old 11-21-2012, 08:34 PM   #14
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I have a little device held together with a 1/4" set screw that is Loctited in. The item is powder coated. The instructions for disassembly are to heat with a propane torch to release the Loctite. It released with no damage to the powder coat finish. The bottom line is it really doesn't take that much heat to release the Loctite.

Good luck, Dan
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