firemanpat, they are still around. Lisle makes them these days.
Lisle 62900 Super Out Extractor Set

powerstroker100 - I hope the jbweld does the trick. If not, have another go at it, but with a torx bit 3/8" drive socket. Do some experimenting with sizes, but you'll probably find the best results with a tight fit, i.e. one you'll have to hammer in solidly, so it cuts flutes into the plug, like the lisle tools above. This probably means removing the drive shaft, besides, worse case, you might have to pull the whole HFCM to get the plug removed, and having the driveshaft already out may give the extra room needed.

I can't recall, is the factory plug steel? I replaced mine with the brass one that has an oversized head outside the housing. As much as it might not be desired, some focused heat from a torch might help loosen it up too.

 

Pull the HFCM cover, clean and PB the plug from the back.

Good luck....

 

If you have the room carefull use AIR CHISEL might shock it loose. No Air chisel a sharp chisel and hammer and tap it loose.

 

ok have not gotten it out yet going to drop the front driveshaft and try using the chisel and hammer or try hammering a 1/4" in there if it does not work I will remove the cover, but if I remove the cover wont diesel fuel continuosly flow out all over?

 

It shouldn't.

 

+1 on the mini torch....expansion/ contraction works wonders on rust.

 

I have an acetlyne outfit that I use almost daily but I'm afraid to try heating the bolt because all the fuel surrounding it I do not want to take the chance

 

First of all, it's DIESEL fuel you are working with, NOT gasoline so you're safe there. Second of all, I'm surprised you haven't removed the manifold cover yet by now. This would be much easier to work with, rather than struggling under the vehicle. If and when you do manage to remove the plug, get yourself the **** style drain used on LCF trucks so you won't have to go through this grief again. The Ford part number for the drain is 6E7Z-9C082-A by the way.

 

thanks chan, is that something ford will have to order specially?

 

Nope. That's a very common "upgrade" by many F-Series 6.0L truck owners. If your local dealer doesn't have it in stock, they should be able to order it and have it for you the next day at the latest. It's not expensive either.

 

m-chan68 welcome to FTF. I know you will be a great asset to us all.

 

If you take the cover off you can Drill the plug out with a smaller then plug drill and pick the threads out with a sharp pick Size drill to leave threads. Small drill first then larger removed a lot of broken bolts this way.

 

Does anyone know if the drain plug needs be removed in order to replace the primary filter?

 

no it dosnt.
is the gasket on the cover reusable?

 

So what happened Powerstroker100? Last I read, you had a stripped out Allen head in your HFCM water separator drain plug. I'm about to remove the HFCM manifold in an attempt to remove the stripped HFCM drain plug and install the new one that can be finger tightened.