Damaged block installing block heater L5240

Adiredneck · Jan 22, 2016

I had two things to take care of tonight.

1). Install a block heater.

2) replace the rubber suction hose that connects to the hydraulic pump. It's cracked and sucking air, causing power steering problems.

Instructions on the block heater call for removing the hydraulic pump to access the frost plug closest to the flywheel. No problem. Area is very tight with the remaining hydraulic lines (steel) surrounding the area of the frost plug. I had the loader removed, but the quick connects were also in my way.

I then took a long Phillips screwdriver and tapped against the edge of the frost plug. It went in maybe 1/8" and stopped. Took my cordless drill and drilled a hole to see if I could pry it off with a pole barn nail or something. Drilled a couple more holes. Finally got the frost plug to spin and was able to grab it with some needle nose pliers. Looked and saw what I had done and freaked out for a minute. The water jacket was maybe 5/16 deep and there is metal right there!

Freak out time over, I collected my thoughts and took a small nail and felt around in the small holes I had drilled.. They are maybe 1/8" deep, 3 of them. Around 5/32" in diameter. No way I could have damaged Anything I tell myself. Block is likely very thick.

Cleaned up the block, installed block heater, re-assembled hydraulic pump, filled with coolant. No leaks. Good deal.

Start up the tractor. Power steering is acting right. Then I notice oil coming out of the exhaust. Rev it up a little, more oil. Shut it down, Freak out again and check the engine oil. $&@k!. Oil is white. Sick to my stomach. 9:30 at night, call dad to explain the symptoms. "Not good". He says.

I'm at a loss for words now. I'll take everything back apart tomorrow and get the exact depths with my caliper. Maybe the only saving grace may be that that the holes are only down in area just below the cylinder sleeve. Seems like it would not have drilled so easily. I couldn't put much pressure on the drill because of everything in my way.

Just sickening...

Any suggestions on how or if there is a fix for this would be greatly appreciated. Maybe it could be accessed from the inside by removing the crank? Does anyone know on this engine what is directly behind the 1st frost plug on the right side?

Luckily I still have my L3400, so I'm not without a tractor.

roadhunter · Jan 22, 2016

Wow. I feel for you. Sounds like something I would do.

dstig1 · Jan 23, 2016

I wish I had some help to offer, but I do not - only condolences. I have done plenty of biffs myself, but this one could be very painful to fix. Sorry man...

TomSeller · Jan 23, 2016

There are certain frost plugs intended for block heaters. The good heater manufacturers list which plug to use. Keep us posted.

Adiredneck · Jan 23, 2016

The block heater is from Kubota. It's the one listed for my machine. Now that I've had a chance to think this over, There is no way I can be into the cylinder sleeve. Seems like compression would have blown a radiator hose or something. Tractor sounds normal when running, nice & smooth.

I hope.... That I am just dealing with an oil to coolant leak. Thinking that I may just need to patch the hole up with something (JB Weld maybe). If it's bigger than that, we'll have to drop the oil pan and get in there with an inspection camera to see what's up.

Staying positive... Worst thing that could happen is It that we have to replace the block. I've got an uncle that does a lot of excavation work. He does his own work on everything, trucks, excavators, dozers, etc.

Dad is coming over this morning. Heavy equipment operator also. Unfortunately this is the first thought in my mind when I woke up today.

npalen · Jan 23, 2016

Hang in there. Issues like this can seem ominous at the time but not so much as time passes.

Adiredneck · Jan 23, 2016

I am learning that the V2403 engine was used in a lot of applications. Complete rebuilt engines are going for $4000.00. Sucks, but not as bad as I thought it would be. I wish I could look at a bare engine block to see what is behind the frost plug.

Toyboy · Jan 23, 2016

Is there any way to could tap the holes and put a short set screw in with some red loctite?

The Deerslayer · Jan 23, 2016

Try to stay as positive as possible. You helped me out quite a bit with advice on the widening of my tires and wish I could return the favor now;but I have little to offer on this one. If your Dad and Uncle are unable to offer a less costly fix, perhaps a call to the local service department or Kubota for input may help. Hang in there and keep us posted.

Adiredneck · Jan 23, 2016

What are the chances KTAC might cover this? Even though I bought it used, it was from a dealer and the insurance was included. Or would this be considered neglect or misuse?

aczlan · Jan 23, 2016

KTAC might cover it.
Dad did the same thing with an L3650 and had to have the engine rebuilt (they tore it down, welded it up then machined it smooth IIRC)... The shop ended up charging twice their quote to fix it.

Aaron Z

Egon · Jan 23, 2016

Does the block have sleeves or is it a parent block.

s219 · Jan 23, 2016

I know that sick feeling pretty well, so I can sympathize.

Is there enough room through the frost plug hole that you could possibly weld the holes up? Really depends on what is behind those holes I suppose. Could be an oil passage, in which case it's going to be hard to fix with welding or devcon or JBweld without messing up the oil passage. With limited space, I doubt a patch could be welded over the holes.

I like the other suggestion of tapping the holes and sealing a screw in -- if there's enough room and depth to get an end-tap in there, cutting some fine threads and putting a screw or plug (even stubby set-screw) may be a perfect option.

Hang in there, try not to give yourself an ulcer.

Adiredneck · Jan 23, 2016

The plan is to tuck it in the back of the garage so the wife's car will still fit. I will drop the oil pan, borrow an inspection camera and some night this week try to find where my hole is. Then I'll determine a plan of attack from there. A call to my uncle confirmed my suspicions and he agrees on the proper plan of attack. He will be here when we inspect everything.

aczlan · Jan 23, 2016

Egon said:
Does the block have sleeves or is it a parent block.

IIRC, the L3650 was a parent block engine.

Aaron Z

countrybumpkin · Jan 23, 2016

Sorry to hear about your mishap, hopefully you can figure out a simple fix after determining the extent of the damage. Oh PICS, we all love pics.

newbury · Jan 23, 2016

Thank you for this thread. Another one to help me temper my DIY activity.

Cat_Driver · Jan 23, 2016

Go get one of these and see if you can look INSIDE

Egon · Jan 23, 2016

Suppositions:
Okay, the oil is white. Indicates water in oil. Indicates the holes allow cooling fluid into the crankcase.
Pressure should be highest on the cooling side.
If those suppositions are right a pressure test on the cooling system should fail.

What I am getting at is that a patch on the pressure side may be held in place by help from the cooling fluid.
Looking at an engine diagram may give a good idea of what's on the other side of the holes. The patch could just be a high temperature epoxy of ??

The clarity of my thoughts here is not the clearest but if correct the OP may have an easy fix??