I have a 2001 5.4l expy and.....

Well i was trying remove a sparkplug with one of those solid thread inserts and it dropped intocylinder #3. I have a timesert kit coming and my hopes are to ream out the spark plug hole and attempt to remove the insert by bringing it up through the plug hole. Of course this is going to be tough and require the insert to be lined up almost perfectly to get it out.
The tools i attempt to use are a magnet that is just small enough to fit into the plug hole, but ffairly powerful. Also plan to use heavy wire with a section of duct tape around the end of it.
I am tryig to negate the need to remove the head to get it out and am looking for any other ideas people may have. Will also have a shop vac on hand, but dont know how much help it will be.
Thanks

 

Would it be possible to remove the intake, unbolt the head and raise the head enough to get the insert out without removing the timing chain or anything else?

 

In one word. NO.

 

How is that even possible? Thread inserts have a lip around the top to prevent them from turning in further than they should. Plus, when backing out the spark plug, the worst case scenario is that the insert backs out of the head and is still on the spark plug. So my question is if it's possible that something else fell into the cylinder?

 

I put another thread insert on the plug, not a time-sert style. Well all the threads in the head that held the old insert are gone so it would just spin and just threaded right off the end of the plug into the cylinder.

 

I have seen this video below. The guy bought one of those inspectors camera, try find one at craigslist.
He use some adhesive to the tip, he was able to look inside to remove the piece of porcelain that fell in the cylinder.
A new camera costs around $200 , I bet you can find one much cheaper on line.

broken spark plug pieces removal ford 3 valve 5.4L 2006 - YouTube

 

What about a shop vac with a smaller clear tube taped to the hose?

 

Harbor Freight has one for $100.
Wireless Inspection Camera - Great Deals on Wireless Inspection Cameras at Harbor Freight

 

Well i have the hole reamed out slightly larger, have to get the magnets and stuff tommorow.

 

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Well I was able to get it out, much to my own surprise. I used a strong flexible magnet just smaller than the plug hole, and a small inspection mirror to see. Took about two and half hours...it went like this.

Recieved my Timesert kit and used the reamer to enlarge the hole and clean it up. After trying all three types of magnets I had purchased ($40!!!!) the only one I felt comfortable using was the heavy flexible one. Laying on an old creeper cushion positioned across the front of the truck and using a small round inspection mirror to see I tried for about an hour to get it out with little progress. I was able to get the insert to start up the hole, but it kept getting hung up. Began discussing the options with the wife of whether to take it to someone or just pull the head and do it myself. Well I decided to give it another go. Rereamed the hole to see if I could get it cleaned up better. Was able to get the insert alighned with the hole, but once again it would hang up. So I started to turn the magnet attempting to see if the insert would thread out. Kept doing this and thought it looked like it was coming out, I pushed down on the magent and it didnt move!!! The insert was actually coming out...kept turning and turning....heart was pounding harder and harder with each thread that I saw come out of the hole. When it came completly out I almost rolled of the front of the truck I was so excited and shocked that I was actualy able to get it out .

I then proceeded to finish the timersert fix and the next morning finished putting everything back together and fired it up. Ran great.

So thanks to all of the suggestions and help guys.

 

Isn't kind of strange that people, that do there own wrenching, get an overwhelming feeling of happiness after we've put ourselves through unbelievable self-torture. Sort of like feeling great after you stop hitting yourself in the head with a hammer!

Glad it worked out for you.

 

If you think the magnets were expensive...pull the head instead.

I'm glad you got it out and I'm even more glad for you that it wasn't one of the back cylinders (4 or 8).

 

Ya i know it was a cheaper fix than what it could have been. But #4 cylinder is repaired with a plug saver like i pulled out. I put that in before i knew about the timeserts. So ill be playing with that cylinder before long.

 

Before you attempt to mess around with it, get yourself about 2 feet of a single solid 14 gauge (not stranded) piece of bare wire wire. Slide the wire down through the spark plug hole until it touches the piston. Then rotate the engine by hand until the piece of wire is as high as possible. This will leave you with the piston all the way up. With the piston up and if the insert tries to fall in, the piston might prevent it from falling, or if it does it'll stop right there at the bottom of the spark plug hole.