Huge Boost Leak Found, How to Fix?

[FJfonda]

Towing the boat home from the last trip I developed a huge boost leak, couldn't get past 20psi boost and EGT's skyrocketed. Finished the trip (slowly) driving by the EGT gauge to try to keep it below meltdown. Diagnosing was difficult as the leak was so big the standard turbo pressurizing leak checking techniques didn't work. Eventually I found the leak to be a rotted expansion plug on the cast iron intake plenum behind the rear lift hoop and under injector #6. The effective hole was over 1/2" in size. I was able to remove the expansion plug and factory glue by working through the drivers inner wheel well and my temporary fix is using a rubber 1 2/3"-1 1/2" expansion plug. So far it is holding at full boost but I am concerned over longevity. I would like to install a factory steel expansion plug but really can not figure out how to do this based on the location.
Has anyone replaced one of these?
Thanks

 

[TConver]

Is it 14 in the drawing attached?

 

[FJfonda]

That is the one, shows up as 16 on my diagram, pt# 05016558aa.
From the drivers wheel well, about a full arms reach.

 

[TConver]

I think you probably have to pull the head to get to it. At a minimum strip everything off that side so you can get into that space. Fuel filter, torque converter heat exchanger, maybe a few more items. Not going to be easy.

Would also be concerned if your rubber plug is too far into the hole it could limit air to number 6 and cause it to run hotter and melt something.

 

[Wayne M.]

Useful info right here.

 

[FJfonda]

Thanks,
That is the same assessment I made. Before installing the rubber plug I looked with a bore scope to see if the rubber protruding would cause any blockage, shouldn’t be a problem.

 

[sag2]

Are there any bolt holes (at least two) around the plug? If so you might be able to make up a press out of plate and push the new plug in.

 

[FJfonda]

Are there any bolt holes (at least two) around the plug? If so you might be able to make up a press out of plate and push the new plug in.

None that I can see, nearest bolts are the rear lifting ring bolts which are perpendicular to the force needed to push the plug in. It may be possible to weld up a jig that uses those holes.....will have to look at that closer.

 

[Motorhead]

If it were between pulling the cylinder head or leaving the rubber expansion plug in when it doesn't block anything, I'd leave the rubber plug in. Buy a spare and leave it in the truck with a wrench to expand it.

 

[SnoKing]

I am for building a jig to press in a new one. I have built a few custom tools over the years. Go for it!

 

[FJfonda]

Thanks for the inputs.... have a spare rubber plug in the boonie box for now. Once things settle down I will be assessing fabricating a jig.