Billet freeze plugs/bypass - Competition Diesel.Com

Gorms · 01-13-2021, 10:04 AM

Popped the rear plug today on way to work, fun. Happened during a spirited run through 3rd gear. Not sure if maybe I didn't set it properly on install, has been completely leak free for 5k miles since I freshened up the motor. Head and block were properly cleaned before I assembled everything, all coolant plugs were lock tighted in, none have leaked until today. (It completely popped out).

I'll be replacing it with a bolted version for sure, just wondering if it is worth it to do the bypass kit? Truck is just a fun daily now, might hook a camper behind it a few times this summer. Not sure what it makes for power, does brake traction in any gear though if not careful. 3k rpm for now, 5x12s, 215pump, and he351/ht60 making about 60psi on close to stock timing.

Truck was not very hot when it happened, just got off highway in 20 ish degree weather, cooled down some between stop lights probably.

***Timbeaux*** · 01-13-2021, 02:29 PM

How often have you been having spirited runs?

Gorms · 01-13-2021, 02:49 PM

More than I should, just about every day I drive it.

I figure its the best way to find the weak links while close to home. I go easy when more than 200 mi from home.

bateman · 01-13-2021, 04:13 PM

Everyday haha nice. Same here. Gotta let em eat.

thatguy69 · 01-13-2021, 05:11 PM

How high do you run your rpms?

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Gorms · 01-13-2021, 05:47 PM

Currently have 3k springs in it, I regularly hit 3k. It seems to defuel starting at 3200, I haven't seen much higher than that

bateman · 01-13-2021, 06:07 PM

I’ve read some threads about the pressure relief vs temp relief. I’ll try to find it. I’m pretty sure I read it here.

zstroken · 01-13-2021, 06:41 PM

Make sure the truck is thoroughly warmed up and several thermostat cycles. IMHO what happens, block/water gets up to temp. Thermo cycles, lets cool water in, hits the freeze plug, plug "shrinks" just a little, and pop! Out it goes. You can also drill a few holes in the thermostat. Also I used a water pump off of an industrial application, it had a larger pulley so it ran slower at a given RPM, trimmed the fins, never had an issue and my truck saw 5000 RPM several times.

thatguy69 · 01-13-2021, 07:20 PM

I've also done the trimmed water pump with good results, and still towed heavy in the summer without getting hot.

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K204DR · 01-13-2021, 10:06 PM

Quote:

Originally Posted by Timbeaux

How often have you been having spirited runs?

hate it when I get the spirited runs,,,,,,,,,

Gorms · 01-14-2021, 11:33 AM

I dont plan on hitting 5k, but was going to throw in the 4k springs and bump timing to 20 or so degrees,, now that its good and broken in.

Ordered a Keating plug with the threaded plug in it. Where would that get routed to to help with excessive heat/pressure?

Vincejax · 01-14-2021, 04:18 PM

I run a bolted rear plug with no bypass on my race truck with 0.300" trimmed off diameter of water pump fins. Hit 5000+ rpm many times with no issues.

bateman · 01-14-2021, 04:23 PM

Quote:

Originally Posted by Vincejax

I run a bolted rear plug with no bypass on my race truck with 0.300" trimmed off diameter of water pump fins. Hit 5000+ rpm many times with no issues.

So the rest of the plugs are stock or billet block plugs as well? I’ve heard the ones on the head can be a problem too?

Vincejax · 01-15-2021, 08:17 AM

Quote:

Originally Posted by bateman

So the rest of the plugs are stock or billet block plugs as well? I’ve heard the ones on the head can be a problem too?

Rest of plugs in block are also bolt in. Still have stock press in plugs in the head. I have blown the plugs in the head before trimming water pump, no problems since.

bateman · 01-15-2021, 10:33 AM

Good to know. Thanks

Muddin_dude06 · 01-18-2021, 05:58 PM

I did a bolt in with a -4 line running from it up to the heater line. Everyone used to complain that a full 5/8” line would make it take forever to warm up because it was bypassing so much. So I figured a smaller line will still bypass some but not enough it take a long time to warm all the way up but still give a place for excessive pressure to go.

kawi600 · 01-20-2021, 02:03 PM

How are you getting at that rear plug? pulling the trans back?
This is something Id like to do, but have never had a plug fail. Maybe just leave it alone.

gman99 · 01-20-2021, 02:40 PM

I used a bolted billet plug and a Watts Valve set around 50psi that bypasses to the upper radiator hose with 5/8" heater line. Supposedly the fringe benefit is that it allows more coolant to flow around the rear cylinder at high rpms keeping it from getting as hot and pinching the rings like we've seen so many times. Spins to 5k no issues and when i tore it down #6 looked perfect.

Gorms · 01-21-2021, 04:49 PM

I was thinking of running a regular 5/8 line back to the extra nipple I had below the oil cooler, from when it was an auto. Would that be on the right side of the cooling system?

zachu812 · 01-22-2021, 07:54 AM

I wouldn't bother with a bypass personally, get a bolt in plug and forget about it.

01-13-2021, 10:04 AM	#1
Gorms Name: Gorms Title: Diesel Enthusiast Status: Not Here Join Date: Apr 2012 Location: Dighton Member`s Gallery Posts: 128	Billet freeze plugs/bypass Popped the rear plug today on way to work, fun. Happened during a spirited run through 3rd gear. Not sure if maybe I didn't set it properly on install, has been completely leak free for 5k miles since I freshened up the motor. Head and block were properly cleaned before I assembled everything, all coolant plugs were lock tighted in, none have leaked until today. (It completely popped out). I'll be replacing it with a bolted version for sure, just wondering if it is worth it to do the bypass kit? Truck is just a fun daily now, might hook a camper behind it a few times this summer. Not sure what it makes for power, does brake traction in any gear though if not careful. 3k rpm for now, 5x12s, 215pump, and he351/ht60 making about 60psi on close to stock timing. Truck was not very hot when it happened, just got off highway in 20 ish degree weather, cooled down some between stop lights probably. __________________ 98 12V qclb, NV4500, 5x12s, HE351/HT60 07 Mega, 5.9 auto bone stock 01 TDI Jetta 5spd

01-13-2021, 02:49 PM	#3
Gorms Name: Gorms Title: Diesel Enthusiast Status: Not Here Join Date: Apr 2012 Location: Dighton Member`s Gallery Posts: 128	More than I should, just about every day I drive it. I figure its the best way to find the weak links while close to home. I go easy when more than 200 mi from home. __________________ 98 12V qclb, NV4500, 5x12s, HE351/HT60 07 Mega, 5.9 auto bone stock 01 TDI Jetta 5spd Last edited by Gorms; 01-13-2021 at 02:52 PM.

01-13-2021, 05:11 PM	#5
thatguy69 Name: thatguy69 Title: Too Much Time Status: Not Here Join Date: Jul 2011 Location: Mansfield Ohio Member`s Gallery Posts: 2,023	How high do you run your rpms? Sent from my SM-N970U using Tapatalk __________________ 1999 Compound 24v Rust Rocket 2008 F350 P24v/Allison

01-13-2021, 06:41 PM	#8
zstroken Name: zstroken Title: For $$$ your name here Status: Not Here Join Date: Sep 2006 Location: Western Michigan(by the lake) Member`s Gallery Posts: 23,151	Make sure the truck is thoroughly warmed up and several thermostat cycles. IMHO what happens, block/water gets up to temp. Thermo cycles, lets cool water in, hits the freeze plug, plug "shrinks" just a little, and pop! Out it goes. You can also drill a few holes in the thermostat. Also I used a water pump off of an industrial application, it had a larger pulley so it ran slower at a given RPM, trimmed the fins, never had an issue and my truck saw 5000 RPM several times. __________________ 2008 4x4 Megacab, 68RFE 97 Dodge gone.... 24V P-Pump Mafia member #1(retired) Thanks to Mumau Diesel, Goerend Transmission, Northeast Diesel Service! Last edited by zstroken; 01-13-2021 at 06:43 PM.

01-13-2021, 07:20 PM	#9
thatguy69 Name: thatguy69 Title: Too Much Time Status: Not Here Join Date: Jul 2011 Location: Mansfield Ohio Member`s Gallery Posts: 2,023	I've also done the trimmed water pump with good results, and still towed heavy in the summer without getting hot. Sent from my SM-N970U using Tapatalk __________________ 1999 Compound 24v Rust Rocket 2008 F350 P24v/Allison

01-13-2021, 04:13 PM	#4
bateman Name: bateman Title: Too Much Time Status: Not Here Join Date: Feb 2019 Location: Alabama Member`s Gallery Posts: 2,672	Everyday haha nice. Same here. Gotta let em eat.

01-13-2021, 05:47 PM	#6
Gorms Name: Gorms Title: Diesel Enthusiast Status: Not Here Join Date: Apr 2012 Location: Dighton Member`s Gallery Posts: 128	Currently have 3k springs in it, I regularly hit 3k. It seems to defuel starting at 3200, I haven't seen much higher than that __________________ 98 12V qclb, NV4500, 5x12s, HE351/HT60 07 Mega, 5.9 auto bone stock 01 TDI Jetta 5spd

01-13-2021, 06:07 PM	#7
bateman Name: bateman Title: Too Much Time Status: Not Here Join Date: Feb 2019 Location: Alabama Member`s Gallery Posts: 2,672	I’ve read some threads about the pressure relief vs temp relief. I’ll try to find it. I’m pretty sure I read it here.

01-14-2021, 11:33 AM	#11
Gorms Name: Gorms Title: Diesel Enthusiast Status: Not Here Join Date: Apr 2012 Location: Dighton Member`s Gallery Posts: 128	I dont plan on hitting 5k, but was going to throw in the 4k springs and bump timing to 20 or so degrees,, now that its good and broken in. Ordered a Keating plug with the threaded plug in it. Where would that get routed to to help with excessive heat/pressure? __________________ 98 12V qclb, NV4500, 5x12s, HE351/HT60 07 Mega, 5.9 auto bone stock 01 TDI Jetta 5spd

01-14-2021, 04:18 PM	#12
Vincejax Name: Vincejax Title: Too Much Time Status: Not Here Join Date: Apr 2018 Member`s Gallery Posts: 327	I run a bolted rear plug with no bypass on my race truck with 0.300" trimmed off diameter of water pump fins. Hit 5000+ rpm many times with no issues.

01-15-2021, 10:33 AM	#15
bateman Name: bateman Title: Too Much Time Status: Not Here Join Date: Feb 2019 Location: Alabama Member`s Gallery Posts: 2,672	Good to know. Thanks

01-18-2021, 05:58 PM	#16
Muddin_dude06 Name: Muddin_dude06 Title: ... Status: Not Here Join Date: Sep 2007 Location: Chandler OK Member`s Gallery Posts: 2,541	I did a bolt in with a -4 line running from it up to the heater line. Everyone used to complain that a full 5/8” line would make it take forever to warm up because it was bypassing so much. So I figured a smaller line will still bypass some but not enough it take a long time to warm all the way up but still give a place for excessive pressure to go. __________________ '96 2500 4x4 5sp. 3” Full Long arm lift w/35's ValAir DD Clutch w/ Input DFI 5x.012’s, O-ringed, 625’s Hamilton 178/208, pushrods, PDD street springs, S362sxe/.7WG ‘12 LML crew cab swb 4x4 RC 3.5” lift with 33’s Anarchy tune 5” exhaust w/ Jones 5050XL

01-20-2021, 02:03 PM	#17
kawi600 Name: kawi600 Title: got Coal for Christmas Status: Not Here Join Date: Jun 2008 Location: communist urban hell Member`s Gallery Posts: 861	How are you getting at that rear plug? pulling the trans back? This is something Id like to do, but have never had a plug fail. Maybe just leave it alone. __________________ Psalm 144 Psalm 37:10,11 Isaiah 65:20

01-20-2021, 02:40 PM	#18
gman99 Name: gman99 Title: Diesel Enthusiast Status: Not Here Join Date: Sep 2012 Member`s Gallery Posts: 224	I used a bolted billet plug and a Watts Valve set around 50psi that bypasses to the upper radiator hose with 5/8" heater line. Supposedly the fringe benefit is that it allows more coolant to flow around the rear cylinder at high rpms keeping it from getting as hot and pinching the rings like we've seen so many times. Spins to 5k no issues and when i tore it down #6 looked perfect. __________________ 98 QCLB 4x4 12V, ARP625+ Studs, 14mm mains NonIC pistons, Ported head, Marine Cam, Hamilton Pushrods and Tappets, BeeHive springs HE351cw over Billet S475, 4KGSK, 5X.018's, 7mm DV's, 24 Degrees Timing, 5" Exhaust, TCS Input, DPC Converter, Firepunk Competition Rebuild Kit

01-21-2021, 04:49 PM	#19
Gorms Name: Gorms Title: Diesel Enthusiast Status: Not Here Join Date: Apr 2012 Location: Dighton Member`s Gallery Posts: 128	I was thinking of running a regular 5/8 line back to the extra nipple I had below the oil cooler, from when it was an auto. Would that be on the right side of the cooling system? __________________ 98 12V qclb, NV4500, 5x12s, HE351/HT60 07 Mega, 5.9 auto bone stock 01 TDI Jetta 5spd

01-22-2021, 07:54 AM	#20
zachu812 Name: zachu812 Title: Too Much Time Status: Not Here Join Date: Apr 2016 Member`s Gallery Posts: 419	I wouldn't bother with a bypass personally, get a bolt in plug and forget about it. __________________ 1995 RCLB 4x4: H-pump, 5x.012s, HX35 2001 RCLB 4x4: H-pump, 6x.013s, S472/S488 EdzGarage, Matt's Diesel Supply, HTS Transmissions