Engine/Transmission (1998.5 - 2002) Enviroguard plug help

[DodgeWarlock]

Among other things we're doing on the 01 right now we are installing an Enviroguard breather assembly. The problem of course is the plug. Our is cupside up and seems to be made of metal. It is also pushed in about 1/8".



My question is for those who have installed this before. After reading, several of the posters said they finally had to just push it into the pan. I tried doing it by hand with a bolt with no luck. Had no luck tapping bolt with a wrench either. My next attempt is going to be to fish some 1/4" rod down from up top and try to drive it in. How did others push it in?

 

[MVieira]

Warlock, I talked to the Cummins West shop foreman in Sacramento and they had installed quite a few of the Enviroguards on Dodge pick-ups and Cummins powered motor homes and they always pull the vacuum/power steering pumps off and then punch a hole in the plug with an awl and then screw a sheet metal screw in it and with a small slide hammer they pull the plug out the top. It is a little more work that way but it is 100% successful. I used the bolt in the plug method and that worked for me. Driving the plug into the pan would be my last resort. It shouldn't cause any problems but they are usually loc-tited in and you will be driving that contamination in also. Plus I really don't like the idea of the plug rattling around in the oil pan. Not trying to scare you, because as a mechanic for the first 14 years at the CAT dealership I work for, you would be surprised how many times I tore engines down and found; wrenches, feeler gauges, screwdrivers, and misc. nuts, bolts, and washers that were in the oil pans that never hurt anything.

Regards, Mike.

 

[rotohead]

I pushed mine into the pan about two years ago and still no problems. I look for it every oil change.
I also talked to a couple Cummins wrench turners and they said the style of plug varies depending on the year. Early years the plug was just a 'cap' (much like a bottle cap would look) with no lip around the edge. This was the way mine was so pushing it in was very easy. I also changed the oil at the same time and noticed little to no locktite in or around the hole. Later years the plug was changed to having a lip around it (much like a top hat would look) and you could get a flat bladed screwdriver or something like that under the lip and pry it up and out. On mine I was surprised at how little effort it took to push it into the pan. I could never get a bolt to thread into it. I did this all when I was changing the seal in the vacuum pump so the vacuum/power steering pump assembly was removed. It does make it easier to get at and view. Good luck. The Enviroguard is one of the best additions I've made.

 

[DodgeWarlock]

Decided to try making a tool to reach plug without pulling the ps/vacuum pump assembly. A 3' piece of 1/4 threaded rod with a cap nut on one end and a 30* bend about 3" from the other end is what I wound up with. If you fish it down from the front of the block by the timing case it will get close enough to flex into the hole. Then just tap the capped end to drive the plug into the pan. It's easier with an extra hand, but one person can do it. I'm going to try to post a couple of pics.

 

[JLandry]

Great idea... thanks for sharing it.



John L.

 

[DodgeWarlock]

Thanks. It's simple but effective and cheap. I'm having trouble getting my pictures right, but I will repost them when I figure it out. You can sort of see what a mess the original setup made when it failed.

 

[DodgeWarlock]

I think I finally figured this picture thing out... . maybe.