when I was replacing the spark plugs on my 2001 5.4 I was able to replace 7 of them. and I thought I would just worry about the other at a latter date well today was that date and i still am not able to take the plug out i have soaked in pb blaster a ACdelco brand rust dissolver with heat valve. and no socket that i have will grab the plug i have tried 14mm to 16mm and 5/8 is what i used to replace the other 7 without issues but it feels like it just bottoms out on the bottom of the spark plug well and all of them just spin everything i have tried in my years of experience and i have yet to get this 1 plug out i blew it out and then sprayed the pb blaster and blew it out after about 2 hours and nothing.
i do not want this one plug from keeping me from finishing this simple task any advice or tips well anything at this point would be great

 

Find a 12 point socket that fits real tight and tap it onto the plug hex with a hammer then use an air hammer set low. Or find a reverse fluted e-z out style socket and do the same. I have had luck with a1/2" drive air hammer set real low so you can just get the air hammers to actuate in the gun, use air tool oil in the gun. The low slow blows seem to do the job where simply applying reverse torque via a ratchet will not. Im not sure if you can find a reverse fluted e-z out style socket thats deep enough to go over the plug porcelain. You could try to snap the plug off then use a shallow reverse flute? Head removal is next, yeay! Simple plug change....NOT

 

i have tried 12 point sockets and 6 point i just tried a 9/16 12 point a 5/8 12 point a 14,15,16mm 6 and 12 point sockets and no dice nothing is able to grip

 

i am going to charge my phone and try to get a pic to see if that will tell me what kind of battle i have to fight. i have thought of breaking the plug and trying to get one of my ez outs in there but my luck would be that i wouldn't have any to fit in the hole and i would have to buy a special tool to retrieve the plug

 

this is the best picture i could get maybe someone can see something i cant.
i am to the point of just leaving it until a problem shows up with that one plug and just deal with it when that time comes but if someone has any ideas id be willing to try them out.
i am OCD and this is killing me 7 new plugs and one old plug. hahahaha

 

I would try Kroil or a 50/50 mix of acetone and ATF. Both are far better than PB Blaster as far as penetrating and busting loose corrosion.

 

Silly question...is that some of the rubber boot still in there?

 

So is the socket grabbing at all on the plug ( and it has just stripped ) or is it not going on and the socket spinning?

I am with the other posters ... it you get a socket that is "tight" and won't go down onto the plug and then "tap" it down, you can usually re-form or forge a hex shape onto a plug or nut.

Now, it is very had to tell from the picture but I you sure the socket is going down all the way? Is there anything holding it off? I know you blew it out but take a stiff wire and go around the plug. Make sure something has not gotten lodged between the plug and the well that would be preventing the socket from going all the way down.

I feel for you !

Mike

 

Funny, as I was posting, I see 65Ford is seeing the same thing I am.

This is why I said try a wire or something (welding rod) .... it is hard to tell but I don't see the hex ( I thought is was just my eyes ).

Mike

 

yall might be on to something I never really looked at the picture and it really does look like part of a rubber boot maybe from someone else who might have replaced that plug before and the rubber from the spark plug socket got stuck to the plug

 

Either way, let us know...not envying you right now.

 

it feels like a piece of rubber hopefully this pic will show it better full size I was able to pierce it with a pick and slightly grab with a set of long bent needle nose pliers. but I was not able to pull it up.
what if I was able to take my soldering iron and melt it in half and try to pull it out in two different pieces? would that work? I can grab it but cant seem to pull it up enough and my picks are just long enough to stick out of the well enough to hold on to it. any ideas on how to get it out?

 

Soldering iron might work but you will need a long thin nose to get down beside the plug.

If you are just trying to split it, how about making a tool like a long thin knife that you can just push down and split it ... maybe grind down a hacksaw blade or something like that.

You could also try shoving a screw down either into it or beside it and pulling it up (say a 3" dry wall screw).

Anyone know what "melts" rubber .... acetone or something? Pour it down and let it dissolve the rubber.

Hope this helps ... Mike

 

That spark plug may have been "ejected" in the past and repaired with a Dorman quick repair kit . Dorman kit uses a different spark plug . Check out dorman kit see what kind of plug wrench they use .

If it is Dorman repair , then you will have to redo it with Time-sert kit to make it a permanent repair. Good luck,

 

I vote for chopping the rubber boot with sharp, skinny tools and then hitting it with high pressure air to blow out the rubber bits. Once you can see the hex head then you can re-asses and go from there. Check sites like McMaster Carr for long skinny needle nose pliers and go at it like a wood pecker might work.