Tom,

I tried your method today with no success. I attached a 3/4" deep socket to my cordless driver, which allows me to use the drill to spin the plug, but it won't grab it to be able to move it up and down. So, I used 45 degree pliers to add some pressure to the plug as I spun it with the drill. The only thing I accomplished was to completely file away the thread on the top part of the plug. It still drives back in, so I can still start the truck, but the plugs aren't moving any further than they did.

I began by hitting them with PB Blaster before heading out to dinner last night, then again after I returned and left them to soak overnight. I got the driver set up and attempted to spin out the plugs with a cold motor. Didn't work and I couldn't put any kind of pressure on the plug, so I ran them back in and drove the truck to the hardware store for the 45 degree pliers. Tried once with a hot motor and again with a cooler motor, but still no success. I tried different speeds and even drove them in and out several times. The plugs will drive out the length of the threads, but then won't budge past that. They sit there and spin and spin. I've added more PB Blaster, but I'm not getting any progress whatsoever.

For the record: it may sound like I was being impatient, but I assure you I'm a very patient person and I want this to work, so I went slow and steady as suggested and walked away as mentioned above when it didn't work. I did try faster speeds, but I never went at it full throttle on the drill. It seems like I need something that grabs the plug and allows me to apply pressure up and down with the drill instead of the pliers. Any thoughts?

 

Toms method has you hook the drill right to the glow plug(as if it was a drill bit) That way you can spin it and push/PULL the glow plug. NOT hook a socket to the drill and just spin it and drive it into the head further

 

correct. sorry if i was not clear on that.
so what you are saying is that once it clears the threaded part, it stops coming up??
i have never had one that bad, it is usually just a bit of the tip that is swollen.

 

sounds like your about to frig up the gp threads in the heads.you may be better off to move forward and pull the head.replace the glow plugs with motorcraft plugs this time.they have the best odds of not swelling and becoming stuck like that.

 

That is correct. I don't know how far the tip sticks out into the cylinder, but it seems as though the tips have expanded to the point where they won't allow the plug to move at all beyond what they do. I had one or two with swollen heads that did eventually come out when I first attempted to remove all of them and ended up with the three that won't budge.

As far as reaming out the GP threads in the head, I think the threads on the GPs will get ruined first. Already filed them down at the top of the plug as described earlier with the pliers.

At this point, I've bent the tip of the plugs where they plug in and I'm afraid with all the attempts at pulling them they may now be compromised and running the motor with them still in may result in them potentially falling apart and damaging the motor. Any thoughts on this?

I hate to just park the truck, but I don't have the money to replace the motor and I'm afraid taking the heads off will also be prohibitively expensive as that's something I've never attempted... especially with a motor that has 300,000 miles on it.

 

Does anyone know a mechanic in the Nashville, TN area who might be willing to help me with my issue? I know I cannot afford to take it to a dealer for repair. I feel like when I mention my problem to those who could help me, they pretty much run in the opposite direction, so I'm guessing it's not something most mechanics want to deal with. Any insight on what I should expect to pay to have the heads removed?