This procedure covers the replacement of a single freeze plug (expansion plug) on the 2015-2020 Ford F-150 5.0L Coyote V8 engine, including coolant drainage, plug removal, and installation with proper sealant.

Warnings

Tools required

Parts

• Engine freeze plug (brass or steel) × 1 — Measure existing plug diameter before purchase - common sizes 1.25-1.50 inch
• Motorcraft Orange Coolant concentrate × 1 — VC-3DIL-B or equivalent 50/50 premix

Fluids

• Motorcraft Orange Coolant — 16 qt

Preparation

1. Ensure engine is completely cold (ambient temperature) before beginning work
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal to prevent accidental fan engagement
4. Raise and secure front of vehicle on jack stands rated for vehicle weight
5. Remove engine skid plate or belly pan if equipped
6. Place drain pan under radiator drain valve and engine block
7. Locate the failed freeze plug - use inspection light to verify exact position and accessibility
8. Determine if any accessories or brackets must be removed for plug access (alternator, power steering pump, motor mount, etc.)

Procedure

1. 1

   Drain engine coolant
   Open radiator petcock at bottom of radiator and drain coolant into pan. If freeze plug is located low on block, also remove engine block drain plug on side of engine to fully drain coolant from that area. Allow system to drain completely for 15-20 minutes.
2. 2

   Remove obstructing components
   Remove any components blocking access to the freeze plug. Common obstructions include engine mount brackets, wiring harnesses, or accessory mounting brackets. For side plugs, you may need to remove the engine mount and support the engine with a jack. Document all removed fasteners and take photos for reassembly reference.
   Torque spec

   Mounting Bolts60 Nm (44 lb-ft)

   Electrical Connector Bolts8 Nm (6 lb-ft)
3. 3

   Clean work area around freeze plug
   Wire brush the area around the freeze plug to remove dirt, rust, and corrosion. Clean thoroughly to prevent debris from falling into the coolant passage during plug removal. Wipe area clean with shop towels.
4. 4

   Measure existing freeze plug
   Use calipers or ruler to measure the outer diameter of the existing freeze plug. Record this measurement to ensure correct replacement plug size. Common sizes for the 5.0L Coyote are 1.25", 1.375", and 1.5" diameter.
5. 5

   Remove failed freeze plug
   Using a freeze plug removal tool or slide hammer with adapter, pull the old freeze plug from the block. Alternative method: punch a hole in the center of the plug with a punch and hammer, then pry out using a screwdriver or pry bar. Be careful not to damage the bore in the engine block. Remove all remnants of the old plug.
   ⚠Do not use excessive force on pry tools against the engine block casting as it may crack. Work the plug out evenly.
6. 6

   Inspect and clean freeze plug bore
   Thoroughly inspect the freeze plug bore in the engine block for cracks, corrosion, or damage. The bore must be smooth and cylindrical. Use wire brush or emery cloth to clean the bore surface until it is free of rust and old sealant. Wipe clean with solvent and lint-free cloth. The mating surface must be completely clean and dry.
   ⚠If bore is damaged, corroded, or out-of-round, block may require machining or oversized plug. Inspect carefully before proceeding.
7. 7

   Prepare new freeze plug
   Verify new freeze plug diameter matches the measured bore size. Apply a continuous bead of high-temperature RTV sealant or freeze plug sealant around the outer edge of the plug as specified. Do not over-apply sealant as excess will be pushed into coolant passages.
8. 8

   Install new freeze plug
   Position the new freeze plug in the bore with the convex (domed) side facing outward. Using a freeze plug installation tool or large socket slightly smaller than plug diameter with a mallet, drive the plug squarely into the bore. The plug should seat flush or slightly below the block surface (approximately 1-2mm deep). Drive evenly to prevent cocking. If using expansion-type plug, tighten center bolt to specified torque to expand plug in bore.
   ⚠Ensure plug enters bore perfectly straight. A cocked plug will leak and require re-installation.
   Torque spec

   Freeze Plug10 Nm (7 lb-ft)
9. 9

   Verify plug installation
   Visually inspect plug to ensure it is seated evenly around entire circumference and is at proper depth. Check that sealant has formed a seal around the plug edge. Wipe away any excess sealant. Allow sealant to cure per manufacturer instructions if required (typically 1 hour minimum before refilling coolant).
10. 10

    Reinstall removed components
    Reinstall all components removed for access in reverse order of removal. Ensure all electrical connectors are properly seated. Torque all fasteners to specification. If engine mount was removed, carefully lower engine onto mount and install mount bolts.
    Torque spec

    Mounting Bolts60 Nm (44 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)
11. 11

    Refill cooling system
    Close radiator petcock and reinstall any drain plugs removed. Fill cooling system with Motorcraft Orange Coolant through radiator cap or overflow reservoir. Fill until coolant reaches proper level. Use air bleed funnel adapter if available to help purge air from system. Total system capacity is 16 quarts.
12. 12

    Bleed cooling system air
    With radiator cap off (or bleed funnel attached), start engine and allow to idle. Turn heater to maximum temperature and fan to high speed. As engine warms, coolant level will drop as thermostat opens and air purges. Add coolant as needed to maintain level. Run engine until cooling fans cycle on and off at least twice, indicating full operating temperature and thermostat operation.
    ⚠Monitor temperature gauge closely. If gauge approaches red zone or coolant begins boiling, shut off engine immediately and recheck for leaks.
13. 13

    Check for leaks
    With engine at operating temperature, carefully inspect the new freeze plug area for any signs of coolant leakage. Check all other coolant connections disturbed during repair. If leak is detected at freeze plug, engine must be cooled, drained, and plug reinstalled with fresh sealant.

Reassembly

1. Once cooling system is fully bled and leak-free, shut off engine and allow to cool for 30 minutes
2. Recheck coolant level when cold and top off to proper level at overflow reservoir
3. Reinstall engine skid plate or belly pan if removed
4. Reconnect negative battery terminal
5. Dispose of old coolant at appropriate recycling facility - do not pour into drain or ground

Verification

• Start engine and verify no coolant leaks at freeze plug location after reaching operating temperature
• Verify heater produces hot air at maximum temperature setting, confirming proper coolant circulation
• Check coolant level in overflow reservoir after 24 hours of driving - top off if needed as residual air may purge from system
• Monitor for coolant loss over the next week - any loss indicates leak requiring immediate attention
• Verify cooling fans cycle on and off normally during operation

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