crossover tube plug is rusted!

[Agent2006]

Hello

--replaced the oil adapter gasket

trying to burp the cooling system...cannot get the crossover tube plug loose.

---used vise grips
--sprayed liquid wrench
--spray Kroil

I am soaking the plug overnight in liquid wrench...I cut a funnel and jammed it over the crossover plug boss, filled it with liquid wrench so the whole thing would be submerged all night.

Any other tips/tricks? Eventually I'll do a cooling mod but was hoping to put that off while I fixed other things.

Thanks for any comments....

[dmjarosz]

Blow torch. A little heat goes a long way.

[musclemerc]

WOW!!! Look @ the COT

Don't throw heat at it. Look for a replacement

[Agent2006]

..and look at the aluminum parts, this car was parked near the ocean in NJ, looks like a shipwreck. LOL. I'm think either ON3 or ... does Zack sell/recommend a cooling mod?

(this car is fighting me, but I think i'm winning. Got the interior door panels back in today, replaced

--door module
--drivers door regulator, motor, switches and door panel. Basically everything. I had a good Marauder door shell and smashed door. Thought I could reuse at least the regulator, but NO! apparently a little too much side/side play in the good doors track, window was binding, so I went back in a swapped everything back out.
--r/r door window motor and regulator --- suspected it was bad, but was probably the drivers door master switch, I didn't pick up on the fact that the switches are wired in series. So I got to redo that whole door too.)

other observation --- I drained the radiator to do this repair, got about 1.1 gallons out. I slowly poured one gallon of Zerex in to refill. How much burping do I still need to do? Front of car was on ramps....thanks.

[musclemerc]

On3 is the cheapest option and as far as a cooling mod here's a good option
https://www.mercurymarauder.net/forums/showthread.php?t=107064

[69marquis conv]

I've used a hacksaw blade to cut a groove across the top of the plug, then use a screwdriver and hammer to tap it loose turing left.

[Turbov6Bryan]

Weld a nut to the top of it, then use a bigger tool.

Try and pop it / shock it to loosen it vs continuous pressure

[Invective]

Then DON't reuse it. Get a custom COT cap...mine has the Mercury God's Head.

http://cdn8.bigcommerce.com/s-eg67wux877/images/stencil/1280x1280/products/1245/3533/20160915_131249__97260.1483424 380.jpg?c=2

[sailsmen]

Be aware of any residual flammables when using a flame.:flamer:

[crownvic97]

Go On3, that COT is on borrowed time.

http://i668.photobucket.com/albums/vv45/Markd20000/2003%20Mercury%20Marauder/FB61C1E8-FE1D-4D6A-9D61-16BE74C8A019_zpsblmuk3ji.jpg (http://s668.photobucket.com/user/Markd20000/media/2003%20Mercury%20Marauder/FB61C1E8-FE1D-4D6A-9D61-16BE74C8A019_zpsblmuk3ji.jpg.h tml)

[Spectragod]

Be aware of any residual flammables when using a flame.:flamer:



Unless you are over insured.


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[03Merc]

Tap tap with a hammer, turn it with channel locks.


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[Agent2006]

Thanks guys for all the guidance, this plug is on there been tapping for an hour, tried a punch on the edge....I'm moving on to ON3 -crossover delete! sorry for all these Questions:

1.Street driven car, do I want the two temp sensors? (I assume I do)
2. Do I want the AN/line fitting install kit ? why would people not order an install kit?
3.two rear head fittings or one? --(can this be installed without yanking the engine or heads?)

https://www.on3performance.com/shop/on-3-performance-coolant-crossover-delete-2-port/

final question, does this also replace the metal tubing that runs along the pass side cylinder head? That is pretty severely rusted on my car as well.

Many thanks for your comments!

[Invective]

Thanks guys for all the guidance, this plug is on there been tapping for an hour, tried a punch on the edge....I'm moving on to ON3 -crossover delete! sorry for all these Questions:

1.Street driven car, do I want the two temp sensors? (I assume I do)
2. Do I want the AN/line fitting install kit ? why would people not order an install kit?
3.two rear head fittings or one? --(can this be installed without yanking the engine or heads?)

https://www.on3performance.com/shop/on-3-performance-coolant-crossover-delete-2-port/

final question, does this also replace the metal tubing that runs along the pass side cylinder head? That is pretty severely rusted on my car as well.

Many thanks for your comments!

Thinking I would pay someone to fabricate a stainless COT from scratch. Yeah, I know it won't be cheap.....

http://i299.photobucket.com/albums/mm288/larryo340/My%20Marauder/88c5540d89e87dde9d48f4e41728c5 e6_zpsxb1azzn3.jpg

[crownvic97]

Thanks guys for all the guidance, this plug is on there been tapping for an hour, tried a punch on the edge....I'm moving on to ON3 -crossover delete! sorry for all these Questions:

1.Street driven car, do I want the two temp sensors? (I assume I do)
2. Do I want the AN/line fitting install kit ? why would people not order an install kit?
3.two rear head fittings or one? --(can this be installed without yanking the engine or heads?)

https://www.on3performance.com/shop/on-3-performance-coolant-crossover-delete-2-port/

final question, does this also replace the metal tubing that runs along the pass side cylinder head? That is pretty severely rusted on my car as well.

Many thanks for your comments!

1. Yes, two sensor
2. That’s up to you, I did and I was happy with the lines and fittings it came with.
3. This is completely up to you as the kit is designed to allow you unlimited flexibility in how you design your cooling system. I used two, D/S routed to the thermostat housing port, P/S to the Heater core. I deleted the PCV cooler line and plugged it with a silicone cap. If you route yours the same way as me it will delete the metal line you are referencing. You can do it all in the car, intake manifold removal will be needed to install the fittings.

If you have any other questions or want some pics send me a message.

[lji372]

Thinking I would pay someone to fabricate a stainless COT from scratch. Yeah, I know it won't be cheap.....

http://i299.photobucket.com/albums/mm288/larryo340/My%20Marauder/88c5540d89e87dde9d48f4e41728c5 e6_zpsxb1azzn3.jpg

I’m on it :rolleyes:

[Invective]

I’m on it :rolleyes:

Were you the fabricator who made some but couldn't sell them, or they took much longer to sell than anticipated? :o

[lji372]

Were you the fabricator who made some but couldn't sell them, or they took much longer to sell than anticipated? :o

I made a 2 piece version, specifically for supercharged conversions.
The new version will be closer to the stock tube with the ability on my end to alter for supercharged fellas.
Yes they will also be made from stainless steel. :2thumbs:

48621

[Agent2006]

details? thanks

[Invective]

I made a 2 piece version, specifically for supercharged conversions.
The new version will be closer to the stock tube with the ability on my end to alter for supercharged fellas.
Yes they will also be made from stainless steel. :2thumbs:

48621

Cool!:coolman:

[Spectragod]

I made a 2 piece version, specifically for supercharged conversions.

The new version will be closer to the stock tube with the ability on my end to alter for supercharged fellas.

Yes they will also be made from stainless steel. :2thumbs:



48621



^^^these^^^ are the bomb!!!


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[musclemerc]

^^^^Yep!!!!

[Agent2006]

when might these be available?

[Invective]

when might these be available? I'll buy one as a spare. Prepaid will be fine if necessary. It will stay with the car/estate until sold, along with the rest of my MM paraphernalia and anything I acquire into the future. Currently enjoying my MM as a 'daily driver' while I'm here in FL on a temp(?!?!) basis.:cool:

[mvptech1]

Are there any for sale still? I have the same problem, the fill cap is frozen solid. Me, and two mechanics have broken ratchets trying to break this thing free. Please let me know.

[Agent2006]

Try my summit radiator cap splice in the upper rad hose. Then you don't need to take that crossover cap off to bleed it. 1000 miles on mine so far....$24 bucks at summit.

[03Merc]

Are there any for sale still? I have the same problem, the fill cap is frozen solid. Me, and two mechanics have broken ratchets trying to break this thing free. Please let me know.



Turn with channel locks, 1/4 inch extension in the square, tap it with a hammer. Some heat may help, then throw that plug away!!


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[Agent2006]

I heated the Devil out of that thing, used channel locks, tapped it with hammers...would not budge.

[03Merc]

I heated the Devil out of that thing, used channel locks, tapped it with hammers...would not budge.



Sheesh! Has it EVER been opened!? Haha


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[Agent2006]

.... my car was from Maine and Rhode Island, mvptech is from Mass...salt laden hellholes the rest of the country can scarcely imagine....ok Ohio guys know how it is...

[MyBlackBeasts]

.... my car was from Maine and Rhode Island, mvptech is from Mass...salt laden hellholes the rest of the country can scarcely imagine....ok Ohio guys know how it is...


Removing salt rusted parts is a skill northern mechanics learn.


Southern mechanics see northern rust and look like deer in headlights = snap, snap, snap... :D

[Shinker]

Yeah I hate rust. Usually the blue flame crescent is the only solution but that tube is pretty thin and flimsy. I have my crossover tube off the engine and after looking inside at how it was made I was not impressed. Guess it did the job but I think I will just clean it up and set it aside to look at. I admire your tenacity though Agent2006. My 03 is pretty rusty too but I wanna save it just like you