Glow Plug Tips Snapped Off
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Joined: Apr 2004
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Glow Plug Tips Snapped Off
What A Day!!
Truck wouldn't start all of a sudden, checked gp's and all eight were bad, checked relay and controller and found both fusible link wires from relay fried. Spliced in new wires and 24 volts to all eight gp's now there. Here comes my major dilemma! While replacing the glow plugs - Three glow plugs all on the passenger side the tips snapped off while removing and went right into the combustion chambers. Wondering two things. 1) Did they probably get too hot and warp when the fusible links went bad. and the major one 2) How bad is it going to be to pull the head off to retrieve the metal in the combustion chamber. I have an 86 F250 4x4 with 6.9 and only 95K miles on the engine. Don't have a cherry picker either. I am an absolute beginner to diesels and am wondering just how much time, talent and ultimately Money this little fiasco is going to cost me. Any advice will be greatly appreciated.
Truck wouldn't start all of a sudden, checked gp's and all eight were bad, checked relay and controller and found both fusible link wires from relay fried. Spliced in new wires and 24 volts to all eight gp's now there. Here comes my major dilemma! While replacing the glow plugs - Three glow plugs all on the passenger side the tips snapped off while removing and went right into the combustion chambers. Wondering two things. 1) Did they probably get too hot and warp when the fusible links went bad. and the major one 2) How bad is it going to be to pull the head off to retrieve the metal in the combustion chamber. I have an 86 F250 4x4 with 6.9 and only 95K miles on the engine. Don't have a cherry picker either. I am an absolute beginner to diesels and am wondering just how much time, talent and ultimately Money this little fiasco is going to cost me. Any advice will be greatly appreciated.
Post Fiend
Joined: Nov 2004
Posts: 5,638
Likes: 1
From: Manitoba
First DO Not crank the engine over.......... Can you see any of the tips in the holes.....do not poke at them.
I would like to ask what brand the GPs were.........
The RT head of course is the worst to do, due to the fact some items must be left suspended in the head to remove it, ie some pushrods and head bolts. You will need a cherry picker or a block and tackle from rafters. I will try and find more info for you.
I would like to ask what brand the GPs were.........
The RT head of course is the worst to do, due to the fact some items must be left suspended in the head to remove it, ie some pushrods and head bolts. You will need a cherry picker or a block and tackle from rafters. I will try and find more info for you.
Last edited by PLC7.3; Feb 5, 2005 at 05:18 PM.
Post Fiend
Joined: Nov 2004
Posts: 5,638
Likes: 1
From: Manitoba
Sorry to hear that............but maybe this will convince others to NOT buy Autolites. The main reason I asked was had they been Beru/Motorcraft I would worry about a stuck controller, but since they are "A"s that is a normal occurrance in a week or two.
I am looking up some info re your problem that will help you if I get it. Your lack of experience has me a bit concerned as a lot has to be removed and re installed. What is your tool box status.
Sent you an email...........
I am looking up some info re your problem that will help you if I get it. Your lack of experience has me a bit concerned as a lot has to be removed and re installed. What is your tool box status.
Sent you an email...........
Last edited by PLC7.3; Feb 5, 2005 at 06:32 PM.
Senior User
Joined: Jan 2005
Posts: 314
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Sorry about your delema. I'm a new owner also. 1988 7.3 4x4. Found one bad GP today (autolite-- they were all just replaced by the previous owner) Replaced it with a Motorcraft. Put never seize on it also. $9 at Auto Zone. Now I am going to replace all of them with Motorcraft before I have to feel your pain too.
Go to your local hospital and borrow their gastrointestinal endoscope grabber thingy. They can retrieve gall stones by looking down ones throat with this thing. The deposit on the rental might be high. Those scopes are in the 10s of thousands of $.
Go to your local hospital and borrow their gastrointestinal endoscope grabber thingy. They can retrieve gall stones by looking down ones throat with this thing. The deposit on the rental might be high. Those scopes are in the 10s of thousands of $.
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Logistics Pro
Joined: Apr 2004
Posts: 4,292
Likes: 5
From: NJ where fun comes to die
Is there any chance a powerful vacuum with a reduced hose down to a small tube, would be able to grab the tips? I never had the problem, just taking a guess.
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Senior User
Joined: Jan 2003
Posts: 305
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From: Penn Valley
Well the heads have to come off. It is not a terribly difficult job, just time consuming and they are heavy mothers. When you do get them off then have them crack checked at the local machine shop. If they are cracked STOP, do not let them mill them down without regard. They can only be milled a few thou and that unofficially. See if the cracks are actually in need of fixing or not anyway.
The heads are not that bad of a job. The Haynes manual, while not the best, is adequate for the job. When I did mine don't think I had to use any goofball tools. You just need a gasket scraper, and a rotary grinder mounted wire brush is nice for the cylinder deck too.
Birken
The heads are not that bad of a job. The Haynes manual, while not the best, is adequate for the job. When I did mine don't think I had to use any goofball tools. You just need a gasket scraper, and a rotary grinder mounted wire brush is nice for the cylinder deck too.
Birken
Fleet Mechanic
Joined: Oct 2003
Posts: 1,764
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From: CentralEastern Utah
Originally Posted by Barndog29
The plugs that came out were autolite, As far as the tips go - all three are completely in the chamber. I looked down with a flashlight and sure enough they are all in the chamber.
I would have put money on that!!! Autolite's are junk!
Elder User
Joined: Oct 2002
Posts: 743
Likes: 1
Search the forums for broken glowplugs. There is a very good article with pictures and everything you need to know. Don't remember who wrote it, but it has a lot of useful stuff.
Autolites suck. I wish I could destroy the plant they are made at, since I almost lost the tip of one once. Only by using a lot of WD-40 and patience did I get through the ordeal.
Basic hand tools and a lot of patience can do the job. Without a cherry picker or something like it, you will have a hard time. It might be easier to take the front clip of the truck off than to lift that head out of that hole without mechanical help.
Autolites suck. I wish I could destroy the plant they are made at, since I almost lost the tip of one once. Only by using a lot of WD-40 and patience did I get through the ordeal.
Basic hand tools and a lot of patience can do the job. Without a cherry picker or something like it, you will have a hard time. It might be easier to take the front clip of the truck off than to lift that head out of that hole without mechanical help.
Post Fiend
Joined: Nov 2004
Posts: 5,638
Likes: 1
From: Manitoba
Once the tip leaves the precombustion chamber and enteres the cylinder there is no retrieval procedure that I've heard or seen. This is why when removing any GPs especially one that gets/is stuck you immediatly bring that cylinder to TDC. This then closes off all escape routes from the precup. Once trapped the tips can with air manipulation in the GP hole and suction at the injector hole be removed in most cases.
One point is only crack the GP loose with a tool then remove them with an 8" piece of fuel hose jammed over the top. That way any resistance to removal is noticed before any tip separation problems arise and corrective action can be done asap.
One point is only crack the GP loose with a tool then remove them with an 8" piece of fuel hose jammed over the top. That way any resistance to removal is noticed before any tip separation problems arise and corrective action can be done asap.
Senior User
Joined: Apr 2003
Posts: 198
Likes: 1
From: Kansas
There was a conversation about "a" solution to this problem a few days ago either here or at DieselStop. They removed the injector, used vacuum at the injector hole. Then used compressed air injected thru glow plug hole to "possibly" help move the broken tip. He had a new shop vac with nothing in the storage area so he could confirm it's removal. He heard it rattle when it came out!
You might try a search and get the full story.
You might try a search and get the full story.
Post Fiend
Joined: Nov 2004
Posts: 5,638
Likes: 1
From: Manitoba
That is the proceedure........ but only when the cylinder is at TDC and the tip is trapped "in the precup". The object is to disturb the tip and swirl it around with compressed air, then the vacuum hopefully pulls it out the injector hole.
Here is Ziggster's article.... http://www.members.shaw.ca/k2pilot/Glow%20plug%20removal%20article.html
Here is Ziggster's article.... http://www.members.shaw.ca/k2pilot/Glow%20plug%20removal%20article.html
Last edited by PLC7.3; Feb 6, 2005 at 01:29 PM.