I pulled the glow plug when the piece fell down since I couldn't attempt to retrieve it any other way. At this point being brittle plastic I'm not going to sweat it. I just hope the metal electrode came out with the top piece (I keep worrying about what-ifs but I do that with every project!)

 

So what is the trick to getting the boots to seat? Cylinder 1 and 7 don't want to seat all the way. 3 and 5 look good. I tried for the last hour to get them seated. Used the removal tool, pushed on them to the pint I was afraid to crack the covers.

Cylinder 1


Cylinder 7


Cylinder 5

 

I have always used the tool to remove and install.
The fingers let you apply even pressure when installing the harness end.
One trick for getting the broken end out (I know it too late) is to take the
valve cover off and use a long flat blade screwdriver to work it back out the hole.

 

Yep using the removal tool to also install. I pushed with everything I had on cylinder 1 with the tool. I decided to pull it to see what was going on. It came out extremely hard and I ended up damaging the new harness! I bought another new one this morning for attempt number two.

Anyway I found the head where the boot goes to be very rough and coated with crusty stuff. I did some cleaning with a round file and light grease but still think I have some more to do. I'm convinced cylinder 1 hates me.

 

Just to update and close off this thread. I got the new harness in. It seemed to fit way better. Both were Ford parts. No idea other then maybe cleaning up the glow plugs bores made that big of a difference. Anyway truck started smoother and after running 15 mins and a few restarts no DTCs. Only things was I blew some oil out the tail pipe but I assumed that would be from oil draining in the cylinders when I took out the glow plugs.

Now on to the other dozen projects I have sitting on my workbench for this thing...