ok so when climbing my hill yesterday the spark plug blew out of the head. The entire ceramic part came out as a whole and the metal part stayed in the head. I attempted to twist it out after soaking it with PB blaster and the nut part just twisted off like paper. This is for my 96 F250 5.8 auto 145K on it.

I Put an easy out in and nothing it wont move even after soaking in pb blaster several times a day prior.

I was told two different things. First if the Easy out doesnt take it out then there are bigger issues going on with the motor. They suggested soaking it in Deep Creep and trying that if not then look for more serious issues with it.

Second option was the easy out will not work with out torches to super heat the head. Since I dont have them the suggestion was to slowing ream the hole increasing in diamter each time then ream the threads once I had it cleaned up to being just under the thread size.

What options do you guys think would be the most viable. Never drilled a head so not confident about that but considering it is a 96 the heads can be healie coiled to cover my if need be.

 

I had kind of the same thing happen with my 94 5.8, one plug twisted off when I was trying to change plugs. Use an oxy-acc torch to heat the plug real good, put the easy out in and the plug base came right out

The only time I have had an easy out work this good, they have always seemed to be an oxymoron because things NEVER came out easy.

 

Sounds like someone forgot the anti-seize....

 

Yes it was the person before me as I bought the truck used.

 

Good Morning, Happy Moanday Wes

 

A little more background info here - in your post title, you used the word 'again.' Did you have this happen before? If so, same cylinder? If yes, I'm wondering if you have a problem in that cylinder (clogged injector causing lean mixture, or a coolant leak into the cylinder) that is taking out the spark plugs.

Well, since you're not against using a Helicoil, here's what I did in your exact same situation a few years ago: I got one of those mini keyhole saws at the hardware store that has a metal cutting blade, such as this one:

Stanley® Keyhole Saw (15-275) - Hand Saws - Ace Hardware

(You can also use a mini hacksaw blade holder to do the same.)

Then, I used an abrasive disc cutoff tool to cut down the end of the blade (the side away from the teeth, of course) such that a couple of inches' worth of the blade would fit through the spark plug shell.

I used this setup to make an outward radial cut through the shell, relieving the stress on the shell such that it could be screwed out. I'm pretty sure that I did get into the threads on the head itself (almost impossible not to when using this method), but I got the spark plug shell out w/o removing the head.

Then it's up to you whether you could clean up the existing threads enough to reuse them, or just to be safe, do the helicoil thread insert.

If an iron head, you can use one of those extension magnets to fish the metallic particles out of the cylinder after all of the threadwork is done.

Good luck, with whatever you decide to do.

 

I have only had this happen to me once and what I did was to take a 3/8" extension and drive it into the remaining portion of the sparkplug and then unscrew it with a ratchet. Sounds like yours is frozen in worse than mine was, tho.

 

hey thanks for the replys, I used the word again because it happened on my 2001 F150 with the aluminum heads. And now that I think about it also had similar issue with dodge where the plug seized into the head. ended up having to take it to a garage and they ended up pulling the head on that one, cyl nevered fired rght after that.

But any ways in this scenario I was driving up the hill really steep incline. and plug blew out. The entire porceline insert came out in one piece.

Then I put a wrench on the nut and it twisted off like tin foil.

Instead of drilling out the rest of the plug I tapped the easy out in until it bit. should I try to drill it out first to see if that makes a diff or should I just use a very thin hack saw blade I think I like that idea better that the drill bit hell of alot more tedious but less threat of damage to head. There is enough sticking out that I could get a pair of needle noise pliers on it if need be.

Oh and to clarify I live in Salty Upstate NY where we see as much salt put on a road as snow falls and this truck has a plow on it and I bought it as is.