Broken Spark Plug

johnny be

Cadet
Joined
Jul 1, 2011
Messages
24
Yeah, just spent three hours this morning trying to get it in. that peice is not going in.
so frustrating.
need help please:)
 

gm280

Supreme Mariner
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Jun 26, 2011
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14,605
Okay, not knowing about your particular engine, I tried to research what info you offered. And I can't find that part in the break down that I've searched. So maybe post your model number and even the actually part number of the new part. Then I, or even others, can offer suggestions. There is probably others that had done what you are trying to do and can lend some advice as well...
 

boobie

Supreme Mariner
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Nov 5, 2009
Messages
20,826
You should have part # 330935 bushing. Do you have the shift lever removed ? If you do the bushing should just push in and lock.
 

Silverton34c

Petty Officer 2nd Class
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Jun 28, 2013
Messages
113
All right...need some more help...was changing out the spark plugs and the one in the back (of course) was rusted through and broke in half when being removed. The threaded portion only and tip are in the block and the rest came out. Suggestions would be appreciated on how to remove this thing!
 

Silverton34c

Petty Officer 2nd Class
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Jun 28, 2013
Messages
113
Any ideas how to remove a broken spark plug from the block? Only the threaded portion and tip are remaining in the block. Suggestions appreciated
 

alldodge

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Mar 8, 2009
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42,610
Any ideas how to remove a broken spark plug from the block? Only the threaded portion and tip are remaining in the block. Suggestions appreciated

I would try an easy out
0508317-23.jpg
 

gm280

Supreme Mariner
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Jun 26, 2011
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I have to agree with AllDodge on his assessment. However, I'd love to hear the story behind this situation. I mean how did you manage to break off the spark plug and leave only the threaded part remaining? That means the metal section you usually have to thread in any spark plug was broken off. Now that is amazing...
 

Silverton34c

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Jun 28, 2013
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113
No special story..apparently there was water or something dripping on the plug and rusted the base away...all the other plugs came out fine...never seen this problem before myself...always wanted to see the inside of a spark plug and now I have...I can look inside the cylinder where the plug goes and still see the spark plug tip and threaded portion...If I could post a picture from my phone I would
 
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gm280

Supreme Mariner
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Jun 26, 2011
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Okay I can believe that. Sorry to hear about it too. I can easily think of ways to fix your broken plug, but it would involve the possibility of getting the tip and such in the cylinder. That's the part you have to keep from happening. My suggestion was to drill with progressingly larger bits until you could collapse the sides of the threaded section towards the center and remove it... But you risk parts getting into the cylinder and the would have to remove the head and clean it out...
 

Tnstratofam

Commander
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Aug 18, 2013
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2,679
So your saying the broken part of the spark plug is in the combustion chamber? Not still threaded into the head right? If that's the case it sound to me like your gonna have to pull the head to get it out. Or am I misunderstanding you?
 

ziggy

Admiral
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Jun 30, 2004
Messages
7,473
this thread was wierd. i saw a reply from the op that said his plug was rusted in. that'd explain breaking it off. i don't see that reply any more, don't know where it went. in my experince, plenty of fasteners on boats that break off due to rust or corroision. not excluding plugs. specially with lack of maint. or water intrusion that's not approached right away. folks break off plugs in jet skis often due to dissimilar metals and electrolysis. again, especially when lack of maint. happens.
while i've never had the experience of breaking off a plug. an easy out would be my first try too. i've broken off my share of various fasteners. not spark plugs, but screw threads is screw thread imho, and an easy out is a good first start. my concern would be with metal shavings falling into the combustion chamber. easy outs don't always hook up to drive right away. sometimes causing metal shavings. ya could remove the head if that becomes a concern for metal shaving or any other spark plug debris that may fall into the combustion chamber. with the head removed that issue is n/a, i'm sure google could answer as to how to get the remaining plug removed. research easy outs on google too. there are different verities. all dodge shows the most common type imho. which is the type i've used. sometimes with success. sometimes not. also, some rust penetrate may also be in order. pb blaster or the likes. i've had pretty good success with pb blaster. fasteners i thought would break off for sure. only to be removed. imho, likely because i used a rust penetrate.
good luck.
drill with progressingly larger bits until you could collapse the sides of the threaded section towards the center and remove it.
imho, that'd be the last straw. do that with the head removed imho. imho, drilling is always the final last straw. there are no other options. if ya drill, ya drill right the first time or replacement parts will be in order.
 

Silverton34c

Petty Officer 2nd Class
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Jun 28, 2013
Messages
113
Appreciate the help everyone! soaking in PB Blaster right now...will try the ez out in the morning...If possible filings, buddy told me to take a shop vac and duct tape a small hose to the nozzle and put it in the cylinder and move it around and it should suck any debris out as it should be dry in there. BTW, my comment is back IDK what happened...weird situation no doubt...no one I know has ever heard of a plug base breaking off on the block...
 

Bt Doctur

Supreme Mariner
Joined
Aug 29, 2004
Messages
19,346
I have seen a few of those issues and have tried heat, threading the inner section, applying red Loctite on a bolt,etc and have had very poor results.
The safest way is to remove the head, drill and retap for the spark plug threads
 

wrench 3

Commander
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Aug 12, 2012
Messages
2,108
This isn't an uncommon problem around here with road salt and neglected maintenance on automotive engines. I am assuming that the center electrode and insulator came out with the outer portion of the plug. If you get a welding torch, heat up the threaded portion that is left in the head and let it cool again, it will turn out very easily. You will still need an easy out to get a hold of it but they usually just about turn out with your fingers.
 

Fun Times

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May 16, 2009
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this thread was wierd. i saw a reply from the op that said his plug was rusted in. that'd explain breaking it off. i don't see that reply any more, don't know where it went.
There were two topics made one was in the Volvo sub-forum and the other in the Merc forum.. Something weird happened during the move to the Mercruiser sub-forum but I was able to recover the Volvo post. See post # 2 now for what you recalled seeing. Sorry for the confusion caused.
 

pro-crastinator

Chief Petty Officer
Joined
Dec 12, 2013
Messages
453
Spark plugs fail.
The failure described requires an easy out - and that is all.
No re-tapping required.

I have experienced this failure once, and have seen it happen one other time.

To help visualize: The broken spark plug is in 3 pieces.
1 piece is in the block. This piece consists of simply a threaded tube. - this piece needs to get gone, and you are good to go.
1 piece is the part with the hex head - that is usually lost on an automotive application, but you may have recovered it in the bilge.
1 piece is the insulator, long and slendor, which is connected to the spark plug wire.

The failure was the result of a manufacturing defect. Impossible to predict. You just got "lucky"

Good luck.
 

Silverton34c

Petty Officer 2nd Class
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Jun 28, 2013
Messages
113
I am happy to say the plug base is out...overnight soak in pb blaster and a ez out did the trick...thanks for everyones help!
 
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