Failed spark plug insert removal
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Joined: Dec 2021
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Failed spark plug insert removal
Hi guys. I just bought a 2001 F250 with the 6.8.
I changed spark plugs and the 4th. Plug back on passenger side would not tighten up. I used a borescope to inspect the hole and discovered it along with the other 9 have inserts already installed. All the other plugs torqued properly and looked fine except this one. The insert seat appears cracked in three places and the insert threads appear to be stripped. How can I remove an already installed steel insert? Could it possibly be drilled out an another time sert or cal-van sert be installed?
I changed spark plugs and the 4th. Plug back on passenger side would not tighten up. I used a borescope to inspect the hole and discovered it along with the other 9 have inserts already installed. All the other plugs torqued properly and looked fine except this one. The insert seat appears cracked in three places and the insert threads appear to be stripped. How can I remove an already installed steel insert? Could it possibly be drilled out an another time sert or cal-van sert be installed?
Hotshot
Joined: Jan 2004
Posts: 19,760
Likes: 1,079
From: St Louis
If it's an aluminum insert, you can likely drill it out. If it's steel, you'll probably have to use a suitable bolt extractor to unscrew it. Lot depends on what it actually is...
Got any borescope photos of the failed insert?
Hotshot
Joined: Jan 2004
Posts: 19,760
Likes: 1,079
From: St Louis
If it's an aluminum insert, you can likely drill it out. If it's steel, you'll probably have to use a suitable bolt extractor to unscrew it. Lot depends on what it actually is...
Got any borescope photos of the failed insert?
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New User
Joined: Dec 2021
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I tried a sprial extractor and it gripped at first then just started spinning. Does anyone have a link to a better extractor? Also how hard is it to take the passenger side head off?
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Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
Wow that's one ugly insert. 
Removing the head might be your only option at this point sad to say. Do keep in mind I'm not familiar with removing an already installed insert so someone here might have a better idea.
Removing the head might be your only option at this point sad to say. Do keep in mind I'm not familiar with removing an already installed insert so someone here might have a better idea.
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Laughing Gas
Joined: Dec 2019
Posts: 893
Likes: 255
From: San Diego, CA
I am curious if getting a quality kit like the Calvan would still work in this situation. The clearance hole drill might knock out all that material anyway since the Calvan inserts are so thick.
Edit, even on the Amazon page it says:
Edit, even on the Amazon page it says:
- High quality oversized steel alloy insert will repair other inserts that fail and has no ill effects from heat transfer
Laughing Gas
Joined: Dec 2019
Posts: 893
Likes: 255
From: San Diego, CA
https://www.wiseautotools.com/blog/f...ow-out-solved/
Time Sert 5553 – Repairs spark plug holes smaller than .663″ (16.8mm).
Time Sert 5600 – Stand Alone Kit that repairs spark plug holes larger than .663″ (16.8mm).
Calvan 38900 – Repairs spark plug holes up to approximately .678″ (17.24mm).
There are plenty of extraction tools out there, and I have had decent success with them. In my experience though, its usually smaller diameter fasteners. You might want to try a specific extraction tool made for the spark plug hole size and thread. If that doesn't work, I think drilling out the old one will be the next best option. With the borescope you'll be able to check you get all the chips out at least. That would be my main concern. Doing all this should be a little less work than dealing with pulling the head!
Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
Cut to the chase and contact CalVan or Timesert for their advice.
