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Join Date: Jul 1999
Location: Boulder, CO, USA
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Oil Gallery Plug Sizes?

Has anyone replaced all the oil gallery plugs with npt plugs? Can you tell me the sizes of plugs and quantity you used? I have measured the rough oil gallery diameters and am putting together a list but wanted to sort of double check. I am planning on tapping every single hole that currently has a stock plug-is there any reason this isn't a good idea? I've heard about people leaving in certain plugs on other applications but I'm not sure that applies here. I would post the list of plugs I think I need but of course it's on my home computer-I can add it later if anyone is curious. Thanks!

Ben

Old 04-01-2003, 10:46 AM
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3/8 NPT. Use a 9/16-in drill to ream the holes to size after removing the plugs, then tap with a 3/8 NPT tap. I used allen head plugs. When you do the rear of the engine, be sure to set the plugs fulsh with the boss area or else they will hit the flywheel. Measure the depth of the thread to the oil passage, if you insert a plug too far, you will block off a passage. This is especially true on the plugs by the oil filter on the front of the case.

Ed
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Old 04-01-2003, 12:44 PM
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Even the 8mm holes? Why not a 1/8" NPT?
Old 04-01-2003, 12:55 PM
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Puny Bird
 
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If you are doing all or most of the plugs then there are 3/8, 1/4 and 1/8 NPT plugs. I don't know the exact count and I can't check till tomorrow.

I'm doing this to 2 cases right now, 1 I bead blasted the other just hot tanked. I cleaned the cases 3 times with a powerwasher then pulled some plugs. Both cases still had crap in the oil passages.
Old 04-01-2003, 01:29 PM
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Plus, if you have a cam/lifter combination go flat, it makes scrubbing the oil galleys much easier to get all the metal out of the corners....

Don't ask me how I know....

Later,
Tom
Old 04-01-2003, 08:26 PM
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My plug size count

I checked my notes:

Front side of engine (impellar)
2x 3/8" NPT plugs
1x 1/8" NPT plugs
1x plug for 20mm diameter hole

Left-Dr side
None

Rear-flywheel
3x 3/8" NPT

Right-Pass side
4x 1/4" NPT plug

I do want to look into this before I buy the plugs because I thought I've used 1/8" NPT plugs for the holes behind the flywheel, so maybe I've overestimated the sizes needed.

Old 04-01-2003, 10:45 PM
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