Cummins 4BT – Expansion Plug Replacement – Removal

Clean the area near the expansion plug of all debris.

Punch, Visegrips
Remove the large expansion plugs (58.06 mm [2.29 in.]) from the coolant passages.
Care should be taken not to drive the expansion plug out and into the water jacket, especially the plug on the end
of the cylinder block.
Service Tip: If it becomes apparent the expansion plug is not going to pivot in the bore, use a center punch to catch
the edge of the expansion plug and pry against the cylยญinder block to pivot the expansion plug out.