Take you time installing the freeze plug with the biggest socket that will fit. Be sure to coat the outer edges with red permatex threadlocker. Knock it in so that the top edge of the flared end (the outside) is slightly recessed into the hole. Once this is done it will never come out.

Granted I did the one on the engine Tom has when the head was on my kitchen table it was easier for me. You should still have plenty of room to do it though. I used a mallet with a heavy head and made small square on blows to the socket.

From the parts catalog illustration, it appears to be.

No. The base of the thermostat housing is somewhat smaller than the portion where the thermostat and the cover go. Believe me- that was my first thought.

Like I said, it was just weird. The first one fought me every step of the way, but the second one stayed straight and just went right in. Same 5 lb. hammer, same 13/16 deep socket. It's cocked about 0.5mm, but it's recessed below the machined surface all around and slathered with RTV, and since I'm leaving town again it'll have several weeks to cure.

no threadlocker? :(

If the bolt wasn't broken off, Id say have a plate made (or make one if you gave the tools) to bolt over the freeze plug, and goop it up with rtv. Surely it wouldn't leak through a freeze plug and a plate bolted down and rtv'ed.

On what?

Joe.. can I has aforementioned block off plate? (send me pics at least?)

i've done a few of these in my life...

it sounds like you already got it out... and a new one successfully in,
in case anyone searches this... this is what i do...

to get it out...
just tap the top or bottom of the freeze plug with a screw driver and rubber mallet... basically it is like you are putting it in crooked, eventually, the part you are hitting will go all the way in and the opposite side will stick out... then you just grab it with some plier, and pull it out...

as for installing them... as everyone mentioned, find the largest socket it will fit on, but for me, just to get the initial part in and even, i like to use a piece of wood that will completely cover the freeze plug... again gently tap with a hammer until the wood is flush... then use the socket to tap it in to give a little recess...

-J

I use a flat plate, two longer bolts with nuts on them and jack the plugs in evenly with old fashioned non-hardening Permatex wiped on the diameter. To be safe, I make up a small strip with two holes for the bolts and install it over the plug. If it weeps, it won't do much damage until replaced or it seals itself. If it blows out...well:crx:

You have a PM.

Yeah, that'd be great if most of that one bolt wasn't a permanent resident of the head now. Still, I'm pretty sure the head will fly off before that plug blows out.