Cornfield creations
1/2 ton status
What to do about a broken spark plug, when the plug breaks off where the threads meet the socket head? All that is left is the threaded part in the head?
CK5
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extracting a broken spark plug
- Thread starter Cornfield creations
- Start date
The best way is to take off the head, but if not that motivated you could try this:
rotate the engine to 180° from firing for that cylinder (TDC with valves rocking for that cylinder) and drill the center of the plug out, using grease on the tip of the drill bit to collect shavings....Do not use oil, as you want to keep the cylinder dry. Do not let tip of drill bit hit piston top. Use an extraction device (easyout etc)again using grease on the tip to catch any debris, then remove plug. When plug is out, use a shop vac to suck out any remaining debris in cylinder....The valves should be slightly open and allow airflow across the top of the piston. Prop open the accelerator to allow airflow in through the intake valve.
rotate the engine to 180° from firing for that cylinder (TDC with valves rocking for that cylinder) and drill the center of the plug out, using grease on the tip of the drill bit to collect shavings....Do not use oil, as you want to keep the cylinder dry. Do not let tip of drill bit hit piston top. Use an extraction device (easyout etc)again using grease on the tip to catch any debris, then remove plug. When plug is out, use a shop vac to suck out any remaining debris in cylinder....The valves should be slightly open and allow airflow across the top of the piston. Prop open the accelerator to allow airflow in through the intake valve.
What engine are you working on? Why did the plug break, were you trying to remove it and it broke or were you installing it when it broke? Is the head aluminum or cast iron?
is it a 5.4 triton ford ? 
thay got this problem bad 
thay got this problem bad 
Never Satisfied
1/2 ton status
is it a 5.4 triton ford ?
I agree, but a lot of them just blow the plug clean out (threads with it).
Cornfield creations
1/2 ton status
It's one of my friends, he is working on a 01 dodge 2500 w/ 360. He called me to see what to try, and I said I'm not sure, but I know where to go to ask!
The truck has 130,000 miles. He believes the plugs were never changed. He bought the truck last year and it started missing. So out of good practice thought to change them, and one snapped off completely.
The truck has 130,000 miles. He believes the plugs were never changed. He bought the truck last year and it started missing. So out of good practice thought to change them, and one snapped off completely.
fmstruck
1/2 ton status
So where's the porcelain? Did it come out with the hex? If so, I've had some success using a hacksaw blade to cut through the threads and then fold the rest out with a chisel or punch. Just be sure not to cut into the seat area where the plug seals against the head. You may still end up with the head off.
HeavyMetal72
1/2 ton status
There are all sorts of broken plug adapters online. Bet you could pick one up at a local parts store. Might even try calling Autozone or O'Reillys and see if they have one to rent. It is a huge problem with the the Fords, so I bet they have one.
Cornfield creations
1/2 ton status
He said the hex part is completely gone. Just the threads are there and is recessed slightly. I didn't see it since he called later and lives on the other side of the county. I thought maybe if the seat is broken off, then it should be a little easier, granted the threads aren't rusty and straight.
sprinklerhead
Newbie
easy out
had the same problem on my v3500 . plug closest to driver , snapped below the hex BUT took the porcelain with it leaving a perfect hole for the easy out (broken bolt extractor) just drive it in keep pressure in as you turn it out. the electrode was driven straight in as i tapped in the easy out. go slow, be patient, dont forget the PB Blaster.. good luck
had the same problem on my v3500 . plug closest to driver , snapped below the hex BUT took the porcelain with it leaving a perfect hole for the easy out (broken bolt extractor) just drive it in keep pressure in as you turn it out. the electrode was driven straight in as i tapped in the easy out. go slow, be patient, dont forget the PB Blaster.. good luck
Cornfield creations
1/2 ton status
He got the plug out, using a center punch and easy out method. Problem is that the electrode is inside the cylinder. Using our snap-on camera he spotted it, but he said it is pinned in there between the piston and the cylinder wall. If we moved the piston up by hand cranking the engine. Would it be possible to suck it out using a shop vac?
I guess I can't really see how it is pinned between considering tolerances in the cylinder. Or magnetizing a screw driver to grab it maybe.
We're trying to avoid pulling the head on this.
I guess I can't really see how it is pinned between considering tolerances in the cylinder. Or magnetizing a screw driver to grab it maybe.
We're trying to avoid pulling the head on this.
sprinklerhead
Newbie
do not move the piston..at wally world homey depot and lows they sell reducers for the shop vac also very small attachment kits one of the vac attachments is a hose that will fit inside the hole. before that if you can find a way to reduce the vac hole and almost get a seal from the hose to the hole , you would be amazed at how hard they pull.. if you have a pvc fitting to go on the shop vac hose and reduce it to something that will fit snuggly to the spark plug hole it should pull it out, if anything WHILE you have the suction on move the piston DOWN, IF it really is stuck. it may just look jammed . sorry to ramble on just trying to explain it the best i can. i have sucked water out of an entire floor of sprinkler pipe like this. it surprised everybody how hard it will pull.... good luck to you.
