Rusted off sparkplug problem

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Aug 14, 2008 | 10:51 PM

midlf

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Rusted off sparkplug problem

I went to change the spark plugs on my '93 F250 4X4 5.8L engine with 106K miles on it. This truck is my Wisconsin snow plow truck, so think RUST. The first plug I pulled came out with the entire porcelain plug body and the steel hex. The rest of the plug is still in the block. It was rusted off just below the hex.

How do I go about getting the rest of the spark plug shell out out of the head? Obviously I am trying to avoid tearing down the engine and taking the head into the machine shop. BTW I only use this truck for about 2000miles/year to do the snow plowing and make runs to the lumber yard and farm supply store.

Aug 15, 2008 | 01:28 AM

Beanscoot

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From: British Columbia

Spray penetrating oil on it liberally, and try using an easy out. At least you won't have to drill a pilot hole in it!

Aug 15, 2008 | 08:34 AM

midlf

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Quote:

Originally Posted by Beanscoot

Spray penetrating oil on it liberally, and try using an easy out. At least you won't have to drill a pilot hole in it!

Yeah - I've already given all of them 4 shots of Kroil. I'll hit it a few more times. I looked up easy-outs and it will take a #6 or #7. Figures that I only have sizes up to #5. You're right about not needing a pilot hole. That is always the worst part of the easy-out process, other than getting out a snapped off easy-out.

I'm hoping someone knows of a tool specifically for this problem. So far I have not found one by using Google.

Aug 15, 2008 | 01:08 PM

Beanscoot

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I can't think of any specific tool, but I think a square cross section easy out will work better than the spiral type. We used to use these to remove pipe plugs at a rebuilder's I worked at years ago, but we also heated the drilled plug with a torch. You probably will not be able to use heat with the engine in place, unfortunately.

I looked at a spark plug and my Proto easy outs, and it seems a number 9524 or 9525 is the right size. If you can hammer the easy out in smartly and unscrew with a square socket on a ratchet, you have a good chance of the piece coming out.

Aug 16, 2008 | 11:50 AM

midlf

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Quick update: Busted a socket twisting on a standard easy-out #5. Tried to get a second plug out and it twisted the hex off the same way and the porcelain came out. Next step is to see if I can get an impact on the easy-out. If that doesn't work then it's time to drill and tap for a repair sleeve. Overall worst case, pulling head(s). I'm also going to try pulling a plug on the left side to find out just how bad this problem may be.

Aug 16, 2008 | 12:08 PM

Beanscoot

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From: British Columbia

An impact is a good idea as the rapid hammering will often unscrew a bolt that otherwise would break off. Did you use a square socket on the easy out?
Are you sure you want to continue taking out the other plugs? If they're not misfiring, perhaps they should stay in until the motor comes out.