First the truck: 1997 F250HD 460/E4OD 3.55LS 4X4

Now the story: I need to do a tune up now that my truck has around 73K on it. Awhile ago, I had bought new spark plugs and set aside a few hours to change them. ?I got my socket on plug #1 and it felt really tight, until it snapped loose. Then the porcelin part of the lug came out with my socket, leaving the metal threads and tip in the head.

I call a local Ford dealer. they say this happens quite a bit and most often, they have to pull the heads to have the metal drilled out. After many hours I was able to remove the remianing parts with an easy-out. I put a new plug in it and drove it out of the garage. This was a few months ago and I am afraid to touch the other 7 plugs that need to be replaced. I have sprayed them down a few times with penetrating oil.

Anybody have this problem or have any advise for the next 7? Should I just trade the truck without tune up or does anybody have a magical potion I can dump on the plugs so they don't break

 

spray them with penetrating oil if you're worried. Spray daily for about two weeks and I bet that will clear up whatever is in there.

I wouldn't worry too much about it though. Usuaslly that happens because the ratchet wasn't held straight. Maybe you need a 1/2" ratchet for better leverage to help you out. Either way, this is rare, and you don't need to worry too much about it. Just be careful.

Are you getting rid of it?

 

Boy this brings back memories. I had a very similar situation. I don't know if you have you truck done yet or not. I have a 1959 Ford C-600 Cabover. The previous owner decided to have the truck rebuilt and then parked for 20yrs in a damp warehouse. Not the brightest of ideas. Well when I aquired the truck I wanted to replace all the spark plugs. Well 20yrs in a damp environment rusted the plugs in the head. I was able to remove all but 3 plugs that broke off in a similar fashion to yours. Took me 3-4 days to get them out working on them off and on. The shoulders had rusted off and I could not get them out with a socket. So I drilled the centers of the plug out enough to get a decent size e-z out in. Make sure to use a vaccum or compressed air and get as much debrie out before starting the engine you dont want bits of metal scoring up the cylider walls. I then installed an e-z out and took one out with no heat. The other 2 plugs I heated with a torch then soaked with PB blaster (the best penetrating lube ever). The heat allowed the Blaster to soak in a little quicker I repeated this procedure several times. You have to be careful and not over heat the head Try to get the area around the spark plug really warm just when it starting to get red. You will have to be very careful not to burn the truck up. I had plenty of room my whole cab tilted forward and the engine is redily accesable. Well good luck

 

the other thing is let the engine get hot then let the plugs cool down.

Remember this simple fact about iron alloys, 90% of your expansion happens by the cherry (dark) red stage. Any hotter you risk burning the heads, and wasting your time anyway.

 

You want to deal with broken plgs? Try working on marine engines sometime. Had to deal with it a minimum of once a month. During spring tuneup time at least 3 times a month.

 

I am glad I am not the only one who has had to fight with broken spark plugs. I think every one should experience it once. And once was enough for me

 

There is a cure for the broken spark plug syndrome. Change them every spring and this crap don't happen.

 

I had this happen once, since then I have used the bronze anti-sieze compound on
my plugs.

 

I use graphite everytime... higher heat resistance.