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Over the weekend I changed my nearly 20 y/o spark plugs, COP's, and boots and I ran into a few problems. The COP in the #1 spot was already replaced but the plug was original. Who ever replaced the COP over tightened the bolt and it snapped while I tried removing it. There is a bit above the surface. I have tried heating it with my plumbing torch. I've tried the 2 nut technique for removing studs. I've tried grabbing onto it with vice grips. Nothing has worked. It's an M5 bolt and looks too small to use and easy out on. I don't have an acetylene torch or a welder. Any ideas on what to do next would be great!
Last edited by Twonky; Aug 20, 2019 at 08:53 AM.
Reason: Typo
That's likely to snap off as well if you're able to get a hold on it. It not too uncommon for steel bolts to get stuck when they're threaded into aluminum. It might be easier to cut off what's left flush with the manifold and then drill it out and retap it.
The easiest thing would be leave it as it is. The COP won't really go anywhere. The bolt nub will keep it place for the most part. You could wedge a toothpick in the COP hole against the nub. That would secure it a little better than nothing.
The easiest thing would be leave it as it is. The COP won't really go anywhere..
^^^This.
Unless you can't sleep at night and you HAVE to remove it, just leave it. Years ago I ran my Lightning tens of thousands of miles and many years with a couple of COP's "rolling free" without any COP bolts to hold them down.
The only trouble I've had with COPs was on my 01 CrownVic.. A few locking tabs of the electrical connectors broke off so they can work loose. The COPs themselves sit fairly securely on the spark plugs.
UPDATE!!! I got a hold of a welder and I welded a nut to the bolt stub and worked it out slowly. If I knew how easy it was gonna be to get the bolt out this way it would have been the first thing I tried!
I won't lie, I was a bit scared. Since electricity takes the path of least resistance, I made sure to clip the ground as close to the bolt as possible and away from the injectors and fuel rail to guide the charge away and keep it from arcing in an unwanted area...like the fuel line . I also disconnected the plugs on the fuel injectors too.
. I also disconnected the plugs on the fuel injectors too.
