Help- 4 broken plugs. What tool do I need?
 

I used the overrated OTC tool and managed to break half the plugs. Used Kroil for a few hour soak too. Tried both by hand and impact. Impact had a better success rate. Anyway, I need to extract the electrodes on 4 plugs. What's the best tool? Does anyone stock it like NAPA or Advanced auto?

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Did you use the OTC 6918? If so that's the one I used. Did you do it on a cool engine? Also did you turn the plugs 1/4 turn and than let them soak?
I let mine soak overnight, I used a ratchet no air tools, I worked them back and forth a few times and they came out.
I think you need the Lisle 65600 broken plug remover, that should do the trick.
Sorry to hear your problems.
...Gage

Yup. I'm on the phone with NAPA now, they have one. $30 more than amazon, but I can have it in 20 minutes and keep on with the project.

The Lisle tool works great . I have used mine MANY times ....

Okay, just got done with the Lisle tool saving my butt. 3 of the plugs have a missing chip of ceramic that I can only assume is sitting in my cylinders. I'm tempted to hope for the best and hope they shoot out the exhaust valves. No way am I going to pull the heads, but maybe I can rig up a hose to my shopvac and try to suck 'em out?

http://i61.photobucket.com/albums/h7...psotlhddyr.jpg

take a shop vac with a long piece of rubber hose on the end and try to suck out the missing pieces

Thanks, off to rig up something.

You need to soak those plugs overnight and run a stiff dose of Mystery (miracle, marvel)? oil at high and low rpms for 2+- days before attempting that job ........much cheaper and easier. Put a gallon of it in 1/4 tank and tach that baby up to 4 grand 5-10 times. Cover those plugs in penetrating oil..............no it won't hydro-lock it.

Well I'm done. I did manage to suck one piece of crap out, but nothing from the other two cylinders. Put it all together and fired it up. Tappy Tappy exhaust leak! My trusty stethoscope pointed it out it was the back passenger side plug. So I pulled it out and put it back in. Whisper quiet! Must of had some junk on the threads.

Worst spark plug change I've ever encountered on any vehicle. I don't plan to put enough miles on the truck to ever have to do that again.

Thanks for the assistance.

They were the original plugs, the revised part number is a one piece design :-X22

I wouldn't use an impact gun/air ratchet/breaker bar/etc on an engine with aluminum heads. Or else you end up with broken plugs or stripped threads in your heads. I set my tq wrench to a lb or two higher than what it calls for them to be tightened and if doesn't break loose I don't force it. Work it back and forth, use penetrating oil, let it soak over night, but don't just try to use brute force to break it loose :-X22

If you use my method next time they will come out like a greased pig. Everybody gets in too much of a hurry with them and pays the price.

This is on your 05 5.4?

I thought only the ecoboost used those stupid plugs? What is wrong with ford?

Yup, all 5.4 and 6.8 3v motors until they went to 1 piece plugs in 2008 (which required a new head design). The updated plugs are still multi-piece, just stronger so they don't twist apart as easily. I also put anti-seize on them so that should help if I ever have to do it again.

I miss my '03 7.3.... stupid spark plugs.

Here's the write up I did...I'm glade that you got them out with out major problems.
https://www.ford-trucks.com/forums/1...l#post14389089
...Gage