New Recall 25S62 released 8/4/25 to dealers for 2024-2025 BS and Escapes with the 1.5L; delivery hold for new vehicles.

[TrueNorthSport]

What is a ball plug in terms of cylinder head manufacturing

[ChatGPT] In cylinder head manufacturing, a ball plug is typically a small spherical or ball-shaped metal plug used to seal an internal drilled passage within the cylinder head—most often in coolant or oil galleries.

Here’s why and how it’s used:

Purpose

• When cylinder heads are cast and machined, internal passages (for coolant flow, oil lubrication, or sometimes fuel injection) are often created by drilling from the outside in.
• These drilled holes allow tooling to reach internal channels, but they must be sealed after machining so fluids don’t leak out.
• A ball plug is pressed into the hole to permanently block it.

Design & Materials

• Usually made of steel, aluminum, or brass, depending on the cylinder head material.
• Spherical shape allows for uniform expansion when pressed in, providing a tight, leak-proof seal.
• Can be solid or hollow depending on application.

Installation

• The ball is pressed into the drilled opening slightly larger than the ball’s diameter.
• Pressing deforms the ball slightly, locking it in place.
• In some cases, a sealant or staking method is added for extra security.

Examples in Cylinder Heads

• Coolant jacket gallery plugs – sealing the end of a drilled coolant passage.
• Oil passage plugs – closing off lubrication drill points to direct oil flow only where needed.
• Sometimes also called a ball plug closure, drill ball plug, or ball expansion plug in manufacturing manuals.

If you’d like, I can also sketch you a cutaway diagram of a cylinder head showing exactly where and how a ball plug is used in sealing coolant/oil galleries. That would make it visually clear.

Just remember … ChatGPT does not always know truth

As far as how many Bronco Sports are impacted, I have no reason to doubt Ford’s analysis of the impacted vehicles

Thank you for this info, don't worry about a sketch, I now have a a good understanding of the function of ball plugs.

I appreciate your comment "ChatGTP does not always know truth ".

And here we thought that AI was going to be the answer to the world's problems ?!

Cheers

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[Dude]

Thank you for this info, don't worry about a sketch, I now have a a good understanding of the function of ball plugs.

I appreciate your comment "ChatGTP does not always know truth ".

And here we thought that AI was going to be the answer to the world's problems ?!

Cheers

All of that was from ChatGPT including the offer of a sketch … it’s always friendly and offering more

yesterday I asked for a recommendation and I got the name of the place .. when I checked it had closed in 2010 so I asked why would you send me 2010 info

always have to double check everything

 

[elvisimprsntr]

My BS was built on November 27th, 2024 so I have absolutly nothing to worry about.

 

[elvisimprsntr]

The tech instructions call for the tech to remove the air cleaner box to be able to see the p/n on the cylinder head.

I can see the P/N tag just under the fuel rail on the RHS. I couldn't get my iPhone camera to focus on it. Gave me an excuse to buy an iPhone articulating endoscope camera. Arrives tomorrow.

I assume the dealers will use a similar method and charge Ford for the full labor hours to remove the air cleaner. Easy $.

 

[elvisimprsntr]

Articulating endoscope arrived today.

Assuming I am pointed at the cylinder head, doesn't appear my P/N is on the list.

4133A24318
PV4E 6049 E46B
094250

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