Broken Sparg Plug

[onejohny]

Hello,

When removing my spark plugs, I broke a seized plug and the threaded portion remains in the engine. I tried using an EZ out bolt extractor and PB blaster. No Luck. I tried some heat using a butane torch and no luck. I'd like to have the car running again soon as I plan on driving the car to Watkins Glen International to watch the vintage races on September 7th. Any ideas for getting the plug out without pulling the head? I just have this feeling I'm going to find more wrong or break a head bolt etc if I pull the head and run out of time. I ordered a gasket set, but didn't order new bolts.

Can I
- Drill out in place?
- use some sort of thermal expansion trick between the aluminum and steel?

How hard is it to pull the head and does anyone have a guide for dummies?

-John
Rochester, NY

[81SPIDERMATT]

what happened with the easy out??.... did it just spin....maybe it was not big enough..... number 5 i think was what worked for me ... but that was a old scout v-8.... not sure if our cars have the same size plugs

snake oil tip.... half acetone and half ATF mixture..... best stuff for loosening stuck bolts and such

[maytag]

is there enough of the plug remaining that you weld a bolt to it, and turn it out?

Sometimes a rapid succession of heat and dry ice will break things loose. But be careful with the heat: this is an Aluminum head!

[onejohny]

The easy out grips fine but I'm breaking sockets with the torque that will not even budge the plug. Same reason I wouldn't try welding a nut, it would just snap off.... I think the easy out is making the threads even tighter if anything.

I was thinking of using canned air upside down to freeze it after heating it with a torch or heatgun next.

Or drilling and trying to pick out the threads. I'm just afraid the metal is bonded/fused together. I used a two foot pipe for leverage to try to break it loose and it didn't budge.

[fiat218]

The easy out grips fine but I'm breaking sockets with the torque that will not even budge the plug. Same reason I wouldn't try welding a nut, it would just snap off.... I think the easy out is making the threads even tighter if anything.

I was thinking of using canned air upside down to freeze it after heating it with a torch or heatgun next.

Or drilling and trying to pick out the threads. I'm just afraid the metal is bonded/fused together. I used a two foot pipe for leverage to try to break it loose and it didn't budge.

all i have to say is WOW, never heard of a spark plug in that damn tight

[majicwrench]

Hmmm, pretty easy head to pull.
So just the threaded part is seized into head?? Hollow, obviosly if you are getting an easyout in it. Did ceramice all come out??
Heat is gonna be your friend if you do it on the car. Did plug budge at all?? Do yiou have a torch?? If it moved, you need to get it moving again, back IN, with whatever lube you desire, acetone and trans fluid good stuff as was said. Then rock it, in,out,in, out, even if it is just 1/8 of a turn. IF your easyout is OUT only, that aint gonna do it.Sheer force is gonna make everything worse.

Yes, you can drill it in car, gotta get all that metal out, grease on bit,magnets, vacuum cleaner. Expect to put a helicoil in when done drilling.
Which hole is it?
If you can get acess, take dremel and small grinder and work slot into what is left of plug. Then try to collapse with chisel and hammer.

Again, pretty easy head to pull. Then take to machine shop. And you gotta buy better sockets

[onejohny]

I had a very good local shop work on it. They tried easy-out, torch, etc. and decided to drill it out. By the phone calls I got, I think they were playing with the car all day. They only charged me 1.5hr. 130 bucks. Sometimes finding an expert is worth it.

[fiat218]

I had a very good local shop work on it. They tried easy-out, torch, etc. and decided to drill it out. By the phone calls I got, I think they were playing with the car all day. They only charged me 1.5hr. 130 bucks. Sometimes finding an expert is worth it.

i agree with you