Would Sears carry the square plug socket? One of mine is starting to round off from the 8mm, although I don't mind buying and trying a 7mm if that's what is available.

Didn't realise what a pita it was going to be to get to those - would have been nice to get at when the hpop reservoir was out of the way... just got it back in too.

 

Sears didn't have the sq plug socket or 8-point when I was there but they did have the spline sockets that worked for me. A 9/32 1/4" drive socket worked also.

 

Our Snap On guy had one on his truck, it is a 3/8 drive but the 1/4" drive fits better.

 

7mm works much better than the 8mm. 8mm is to big. Undo the 13mm bolts that hold the ac compressor out of the way. Easier to get to the front plug.

 

Ended up hitting it three times with PB and took off the hpop resorvior to get room to work.

Used the nose of a good quality crescent wrench and twisted it with a screwdriver through the handle to break it loose.

Thanks for the input.

The irony of all this is that I work in a Snapon factory, but don't usually realize that I need a new tool untill 2 am on a sunday.

 

I'd forgotten all about this thread until I started putting the FRx on another 7.3. (Seeing the age of the post reminds me how long I've actually had my original 7.3 and I'm amazed at how well it still runs.)

That aside - with this (new to me) 7.3 it looks like the last guy who worked on it took the liberty of over-tightening the plugs and stripping them at the same time. Maybe he wanted to make sure they'd be hard to steal.... but judging by his other fixes, it's more likely he was a kludge and had no business under the hood of a truck.

On a more positive note... because of his handy-work... or lack there of... we got an amazing deal on a 7.3.

So far I've been through the crescent wrench, 8 pt wrench, splined wrench (had to tap it on with a small hammer because the head was so badly mauled) and while I have a tiny vice grip, I really don't see it doing anything if the splined socket couldn't hang. Then again, I don't have much to lose by trying at this point.

Plan B (or D if you're counting)... is to mig weld a bolt to the end of it with a head I can actually get a hold on.

If that doesn't work, plans E and F involve choosing between drilling the plug with the cable driven extension on a dremel tool and using an easy-out ... or abandon the FRx until the turbo needs to be out so I can reach it with a real drill.

 

Try some heat. And pulling the turbo is quick and can gain you a lot of access. Don't forget to get the new o-rings before Sunday afternoon if you do pull the turbo. LOL Good luck, stripped bolts suck! The 8 point socket with a battery impact or an air impact turned down might do it if there is anything left of the head.

 

I had an easier time with the drivers side then the passenger side honestly. Penetrating oil and back and forth between vice grips and a 9/32 tiny PITA open end wrench. This one was actually more difficult then expected, for me at least.

 

the photo looks like it could be in Montana, nice truck!

 

You are correct Roland. I bought a 9/32 square socket for mine because a open end wrench was going to spin and strip on mine.