I've posted on another forum but I need ALL the help I can get.

One of my COPs broke the other day. I was able to get it out and it also spit the spark plug...although the threads on the spark plug are OK. I limped it to the closest town and went to Advance Auto and bought Motorcraft Plugs and a Motorcraft COP. I got the new plug in fine.
HOWEVER, I can NOT get the COP retaining bolt out so I can install the new COP. The WHOLE bolt just keeps turning. The head of the bolt is NOT stripped. The 7mm goes on fine and I see the entire bolt turns. I've tried prying up with a screwdriver while I turn---NO go. I've tried needle nose pliers--No go. I can not get the freakin bolt out.

Any ideas??

2003 F150 5.4L 2v

Thanks in advance


---DirtySCREW

 

What has happened is the alum threads have let loose from the manifold and are still fast to the bolt threads with some left near the top preventing removal.
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Once you get it out, you will need to retap new threads for the next larger size bolt.
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You could try using some Muratic Acid from the hardware store and keep dropping some around the bolt with an eye dropper to disolve the alums enough to get the bolt out, then do the repair.
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Muratic Acid is very strong so do not breath it's fumes in or get it on other parts you care about.
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Anytime you remove bolts from alum, always use 'Never/antiseize' on the threads before replacing.
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Bolts that won't back out with reasonable presssure and there is safe room to to so, use heat on the head till nearly red then let it cool.
This often expands the steel enough to break the bond with alum allowing the bolt to be backed out.
Good luck.

 

I had the exact same problem with one of my COP's. Naturally it was the hardest one to get to which made it even harder to deal with. There is a treaded insert molded into the plastic portion of the manifold. It is pretty common for these inserts to turn loose from the plastic and spin with the screw still attached. I was told one trick to get them out if you have a high speed drill or neumatic wrench is to turn them at a high rate of speed heating up the plastic while prying it out at the same time. Then you will have to rethread or epoxy the hole and rethread it back.

 

Westflgator----if I am able to get the bolt out with this method, and after I tap the hole to the next bolt size....do I install the new COP with new bolt and fill in the hole with epoxy? The retaining bolt DOES screw into the head doesn't it? Or is the COP retaining bolt only secured into the plastic manifold?

Thanks for the help

--DirtySCREW

 

get a drill, socket adapter and 7 mm socket. spin the bolt fast enough to heat up the plastic to the point where it smokes just a little. pull the bolt out, use jb weld to secure the insert to reinstall the coil.