Ok so I feel pretty dumb about this one but here it goes. I was installing NEW Beru motorcraft GP's in my 86 6.9. The old one came out fine, no problems. I was wrenching down on the new plugs, nothing too out of the ordinary as I have done this job many times before on different IDI's. I did notice there was a "little" more resistance than usual and then boom, it turned completely freely. I backed it out and sure enough the tip broke clean off right where the threads and glowplug "housing" start. And yes they are the correct GP's. So I have a brand new tip, fully into the head, broken off. I tried an easy out, no luck. So what is my next step. Mind you it is only the actual tip that is broken off.Thanks guys!

 

I would try really hard to get it out with the magnet retriever tool, the one with the small round head and telescopic pole. If that wont work, you have to pull the head or ruin your engine. Dont believe anyone if they tell you the engine can pass it in exhaust, not that they should. That sucks a lot but better to pull the head than replace the engine. If you have to pull heads, just pull both and do a head gasket job while you are in there. Sorry dude.

 

Oh boy, sounds like the hole was full of carbon, the only safe way is to pull the head...

However some have blasted them with their favorite penetrating fluid then ran the motor and allowed the motor to blow them out. WARNING!!! It will come out with extreme speed and force and could damage oneself (or hood) so stay out of it's path!

[edit] Wrekinball, It broke going in, It'll not fall into the cylinder, thus no passing thru. [/edit]

-Enjoy
fh : )_~

 

Ok, so with it not being swelled I "could" use some penetrating oil and run the engine and it should push it self out? I may gamble and try this...It is pretty unlikely that it will fall into the combustion chamber right? Remember this happened when I was installing a brand new plug...the tip is broken flush so there is nothing to grab onto. Thanks for the help guys. Dave what do you think?

 

Seems confusing as to where it actually broke. Well I guess we shall see.

 

From what I read it broke at the thread base (start of tip) on the way in, thus it should blow out safely providing no one is in the way and it don't go through the hood!

I would normally not recommend this for most broken tips, However in your case I personally would try and blow it out, I'd lay a piece of the thickest plywood I have laying about on top of the motor blocking the projectile path.

The chances of it getting sucked in is slim, the worst that could happen is any one around could be killed by the projectile ... SO STAY CLEAR!

Remember the IDI produces about 400 PSI ... That tip will hurt!

-Enjoy
fh : )_~

 

The plug was almost completely seated when it finally broke. The tip broke to where I can not grab onto it with anything like vise grips or the like. The "glowing" part of the plug is the only part broken off, but it is flush inside the head.

 

another thing you can do is pull the injector and stick an air nozzle in there to try and blow it out.you might wanna ball duct tape on the end of the nozzle to create a seal against the head
maybe a dowel rod and super glue?or a VERY small amount of jb weld.providing its not really jammed up in there too bad

 

Two choices: Do the start and attempt to push it out on compression stroke.....or

Bring that piston to TDC before doing anything more........ remove the injector and try to fish part out of the gp hole with a long screw....or push the gp part into the precup.........

Now with a good vacuum sucking in the injector hole..... spritz compressed air into the gp hole ......... this should stir up the tip and allow it to be vacuumed out of the injector hole.
Note: this has been done with success on a swelled tip pulled and dropped into the precup.... the only difference is the gp tip on yours will-may be slightly longer... depending on how much is remaining in the GP.

Timing info.........
The timing mark is found on a little plate that is on the front of the engine on the passenger side. The plate is mounted so it is very close to the main pulley on the lower front of the engine which is mounted on the vibration damper. On the side of the vibration damper, is a line, which when lined up with the line marked (O) on the plate, tells you that the #1 piston is at TDC(top dead center) You can see the line on the damper, and it points to the line on the plate with the (barely visible)O mark on it.You'll have to find a way to turn your engine over by hand (Crank/harmonic balancer bolt). Make sure you remove the power wire to the injection pump(so the engine won't start)and then rotate the engine until you can line up the marks.

The engine rotates in a clockwise direction as seen from the front of the truck, and for every 1/4 turn of the engine(crank) each next piston will arrive at TDC. So, When the line on the vibration damper is at the 2 oclock position, cylinders 2 and 5 will be at TDC. When the mark is at the 5 oclock position, cylinders 7 and 6 will be at TDC, 8 oclock has cylinders 3 and 8 at TDC, and back to 11oclock, 1 and 4 will be at TDC.

Cylinder numbers are assigned 1,3,5,7 on the right (passenger USA) bank from front of truck to back, and 2,4,6,8 on the driver's side (USA), front to back. Firing order is 1,2,7,3,4,5,6,8.

OK all the above is true...... to ensure the #1 piston is at TDC compression remove the inspection cover on the oil filler/gear cover. You will see a dowel pin from the IP if it is at 4 oclock that is TDC compression stroke, if it is at 11 oclock that is TDC exhaust stroke.......

 

Pull fuel injector out. Put compressed air in. Viola.

 

Ok...maybe some confusion here. The tip is still stuck into the head. It is not currently in the pre combustion chamber. So I hope the start, blast option works...wish me luck.

 

You can try air through the removed injector hole, it broke going in, it's obviously pretty tight, air compressor pressures (120PSI) Ain't gonna do it is my bet.

It didn't want to go in, it ain't gonna fall in!

Put all the other glow plugs in so it starts ok and run it, it'll pop it out.

As I already stated, I would normally NEVER recommend this procedure for a broken tip, however yours is broken going in, not out, big difference.

Most break off on the way out and are barely hanging on to the inside end of the GP hole if not completely falling off and into the precup or cylinder, yours is stuck all the way through the depth of the hole.

-Enjoy
fh : )_~

 

That is what I wanted to hear festus. Should I soak it in penetrating oil or just start it up and let itself work out?

 

penetrating oil would be a good idea. help lube it and give it a little help to shoot out. id suggest a heavy blanket or a towel folded up over the hole, just enough to stop that projectile from blowing a huge dent in your hood or hitting you. im curious if filling the cylinder with atf, wmo or water would help. being thicker then the air it might give it some extra boost when pushing that thing out.

 

I wouldn't put fluid of any sort in there, if it can't 'flow' fast enough you have just locked that piston. If the others fire, it could cause some serious damage!!