[428ho]

Anyone have a solution to getting a rusted stuck, rounded off, sq head plug out of an Aluminum Muncie housing?

[powerrodsmike]

I'll bet you already tried penetrating oil and vise grips.

Try warming up the aluminum with a torch. the case will expand some and maybe give up the plug.

I never have good luck with drilling hard plugs out of soft materials, the drill always seems to get into the stuff I want to save.

Try welding a big nut to it. Put the nut on the top and fill the center with weld. this will give you something to grab and the heat will help bust the plug loose. If it is stuck now you will probably have to retap the hole some.
hope this helps, mikey

[428ho]

I broke several 8 Point sockets with a long breaker bar, major league pipe wrench finally rounded it. It laughed a vise grips.

Tried some heat, maybe not enough though.
The welded nut idea sounds promising. Nice big heavy hex nut where I can get some leverage. Between that and heat... maybe? Work it back and forth.

Thanks

Brass plug next time around? Teflon tape or anti-seize?

[302 Z28]

I had the same problem a few years ago with a iron pug in an aluminum Muncie housing. Nothing I tried would work. I assume welding a big nut to it might work, but then you run the risk of really mucking up the threads of the case. The problem is over time the two dissimilar metals have corroded into each other and the plug is not really stuck, for all practical purposes it is welded to the case.

I center punched the plug and drilled through it with a 1/8" bit then kept re drilling with progressively larger bits until there wasn't much left of the plug. If you got right in the center of the plug when you get to that point all you have left is a very thin shell with some threads that can easily be picked out. If you are lucky the aluminum threads in the case will pretty much remain. Clean them up and find an aluminum plug and use Never Seize.

Vince

[ckucia]

You can also try welding an old wrench directly to the plug - assuming you have enough room to rotate the wrench completely around if you do get it broken free.

[1931 steve]

Is there any of the plug sticking out of the case? If so I have had good luck using an air hammer and dull chisel bit to get it to turn. Just don't take a big bite so it won't just rip a corner of the plug off. Be careful of heating the aluminum case, I have seen too many melted aluminum parts from just that.

Steve