Help with spark plug that won't come out

[jimh1626]

OK. I was changing the plugs in my 5.7 and all were a little hard to get out as the last owner hadn't changed them in forever. Got 7 out but one broke off and left just the threads. You can see right into the piston. I have tried an easy out for the last 2 days and broke off 3 sockets and used a can of lubricant. Got a crows foot and a gotor socket. It won't budge. Any ideas? I don't want to have to drill and tap or take to a shop but I will if there are no other options.

Thanks

Jim

 

[cavalier858]

Re: Help with spark plug that won't come out

Remove the head and if it can not come out with an Easy Out, then drill it and chast with the proper tap sized to the existing spark plug. You and always plan on an insert heli coil as plan B

 

[reddogg]

Re: Help with spark plug that won't come out

Hate to say it, but you've tried what I would have suggested. From my view it's machine shop time, but hang on and see if any of the other guys has any more ideas. Sorry for you man.

Red

 

[jimh1626]

Re: Help with spark plug that won't come out

I sure as hell don't want to take that head off. I am going to call machine shop tomorrow. I'll pay whatever, just want it back on the water. I was looking at pulling the whole engine to start with because I thought the head gasket blew when all the oil came out Sunday. Thought I was in good shape when I found just a hole in the filter, but was pulling plugs to test compression and this one is really stuck in there. I have never had one screwed up this bad. The previous owner must have not changed plugs in years. They were terrible.

Thansk for your input. Always appreciated.

Jim

 

[jayhanig]

Re: Help with spark plug that won't come out

Others might laugh at this suggestion but I'll throw it out anyway: have you tried applying heat to the threads? Also, I'd be very leery of what may fall back down into the cylinder. At the very least try to stuff a shop vac hose in there to slurp up whatever it can.

 

[rockyrude]

Re: Help with spark plug that won't come out

I read that you used a can of lubricant, was it an off the shelf thread loosener? The best is still the 50/50 mix of acetone and atf. If the threads are that bad let it soak awhile.

 

[nikon]

Re: Help with spark plug that won't come out

Have you tried an easy out WITH an impact gun? Same thing happened to me and the damn thing wouldn't budge, put my 1/2in impact gun on it and seconds later I was installing the new plug.

 

[jimh1626]

Re: Help with spark plug that won't come out

Others might laugh at this suggestion but I'll throw it out anyway: have you tried applying heat to the threads? Also, I'd be very leery of what may fall back down into the cylinder. At the very least try to stuff a shop vac hose in there to slurp up whatever it can.

Good suggestion, but I did buy a propane torch at Wal-Mart and it didn't budge. I am going to get a flexable magnet and put down there when I get it out.

Thanks for the suggestion.

Jim

 

[jimh1626]

Re: Help with spark plug that won't come out

I read that you used a can of lubricant, was it an off the shelf thread loosener? The best is still the 50/50 mix of acetone and atf. If the threads are that bad let it soak awhile.

It was a name brand, can't remember what exactly. I will try the 50/50 mix.

Thanks for your suggestion,

Jim

 

[jimh1626]

Re: Help with spark plug that won't come out

Have you tried an easy out WITH an impact gun? Same thing happened to me and the damn thing wouldn't budge, put my 1/2in impact gun on it and seconds later I was installing the new plug.

No I haven't tried that and I sure as hell will go rent one or buy one if I have to and give it a try.

Thanks for your suggestion,

Jim

 

[jimh1626]

Re: Help with spark plug that won't come out

Great suggestions Guys. Your the best.

Thanks,

Jim

 

[Brokenrod]

Re: Help with spark plug that won't come out

This may sound ineffective, but hear me out.... I had something similar happen a couple years ago. I tried heat, i tried penetrating fluids, nothing worked. finally i read online to heat it up with your torch, then apply a little candle wax to the threads and let it seep in. Worked like a charm. Believe it or not, the bolt came out with little effort. Try it.

 

[sublauxation]

Re: Help with spark plug that won't come out

You may want to look into the ford-truck.com forum and/or google 5.4 spark plug. They've had enough problems with plugs sticking and breaking you may find some good ideas. Definitely take the shop vac and a magnet to it to get out what you can afterewards.

 

[jimh1626]

Re: Help with spark plug that won't come out

This may sound ineffective, but hear me out.... I had something similar happen a couple years ago. I tried heat, i tried penetrating fluids, nothing worked. finally i read online to heat it up with your torch, then apply a little candle wax to the threads and let it seep in. Worked like a charm. Believe it or not, the bolt came out with little effort. Try it.

Nothing sounds stupid at this point. I'll give it a try.

Thanks for your suggestion,

Jim

 

[jimh1626]

Re: Help with spark plug that won't come out

You may want to look into the ford-truck.com forum and/or google 5.4 spark plug. They've had enough problems with plugs sticking and breaking you may find some good ideas. Definitely take the shop vac and a magnet to it to get out what you can afterewards.

I'll do it. And I will get out what I can with a magnet. I am also going to run it with out a plug in it to blow out something I might miss.

Thanks for your suggestion,

Jim

 

[1977 SILVERLINE]

Re: Help with spark plug that won't come out

You could try this technique if you want. Heat the plug up as hot as you can get it and quench it with cold water. This shock of extreme temp change causes the rust to let go. Let everything cool down and give it a try. If it is still stuck try using a penetrating oil like PB blaster and let it soak for a while.

 

[jimh1626]

Re: Help with spark plug that won't come out

I'll give it a try. Thanks. I have used almost a whole can of PB Blaster and it won't budge. It will come out, it just doesn't know it yet.

Thanks for your suggestion,

 

[picklenjim]

Re: Help with spark plug that won't come out

You should bring that piston up to top dead center to keep all the crap up there. Another thing a plumber showed me they do when a pipe breaks off and leaves the threads is take a saw blade and saw a slot straight down to the threads in a couple spots. Then knock them out with a punch. I realize the hole must be pretty small so you would need a really small blade. You know there is the possibility someone cross threaded it in there and the threads are ruined anyway. They do make spark plug thread repair insert kits. About $50 bucks. Just do a search and you will get several hits.

 

[jimh1626]

Re: Help with spark plug that won't come out

You should bring that piston up to top dead center to keep all the crap up there. Another thing a plumber showed me they do when a pipe breaks off and leaves the threads is take a saw blade and saw a slot straight down to the threads in a couple spots. Then knock them out with a punch. I realize the hole must be pretty small so you would need a really small blade. You know there is the possibility someone cross threaded it in there and the threads are ruined anyway. They do make spark plug thread repair insert kits. About $50 bucks. Just do a search and you will get several hits.

I'll give that a try if all else fails. Did the search, might be what I need.

Thanks for your suggestion,

Jim

 

[jmorgan87]

Re: Help with spark plug that won't come out

Sorry if you'v done this, as i've seen heat and penetrating fluid both talked about. But not together.

Be careful, as this is technically flammable..though i've never had an issue. Heat up the threads as hott as possible, then spray it down with PB blaster.

I think this is intended to have similar affects as candle wax, the heat allows the pb blaster to get in to the rust.