Removing Broken Spark Plug

[2052006 10]

Whilst trying to remove the plugs from a 306 xsi, one of them broke - only the middle part came out, leaving the thread still stuck in the engine. How on earth can I get this bit out??! I'm assuming it's pretty well seized in there - will it be a case of head off?

 

Any ideas?

 

Pete

[welshpug 1,657]

8 or 16v?

 

depends how much of the plug came off, you may be able to wind the remains out if it snapped at the top of the threads.

 

post up a picture of the bit that came off if you can.

[2052006 10]

It's an 8v. It's snapped off right below the hex part. I am in deep sh*t as my wife needs the car for work and I already have one Pug in bits on the drive

[swordfish210 20]

I had this happen to me on my mates Escort once. It was a million year old Kent engine with the iron head and it had never been serviced so the plugs were seized in there and one of them snapped on me I had to take the head off, get the plug remains drilled and tapped out and build it all back up again. I'd be that you'd have to do that as well, if it was seized in badly enough to snap the plug then anything you can get on it to try and unwind the remains wont be good enough as you wont be able to get any grip or leverage on it.

[omega 82]

i agree with swordfish as the only other option i can think of is useing a drill which means bits in the engine

[Rom 0]

Is the electrode still in there ? Or is it hollow, with just the outer thread left ?

 

If the electrode is still in there, ive done this trick a few times before..

 

Put a blanket or similar over the engine, so nothing can come flying out.

Crank the engine over, this should fire whats left of electrode out. Leaving just the thread.

Use an easy out to remove whats left.

 

This doesnt always work, but its only failed me a couple of times. If the plug is that siezed in there, it will need drilling and taping. There are companines that can do it in situ, depending on space, or you could try yourself. The problem isnt the drilling, its getting all the swarf out after. As any left in will cause a lot of damage.

[2052006 10]

Thanks for the suggestions. However, I have come to the conclusion that the head will need to come off. @rse!!!! Knowing my luck, bits would fall down the flipping hole, and I'd have to take it off anyway.

[Rom 0]

Get a pic of it, but you may aswell try something if your already residing to takign the head off !

[2052006 10]

Rom - it's just the thread, none of the electrode. How good are these EZout things then and how exactly do they work?

[Rom 0]

So you can see into the bore? Looking through whats left of the plug.

 

Easy outs look like this, just a link at top of google.

 

You wnd them in, and hopefully, they grip onto whats left, and force it out. You would normally drill a hole into a snapped bolt or similar. But you already have a hole to use.

They work quite well. But if its practically welded itself to the head, it might not work. But surely worth a go before taking the head of. Worst that will happen is it will snap, or just wont be able to remove it. Either way no worse than taking the head off.

[2052006 10]

Yes, I can see right through - it's simply the whole "thread" that's stuck in there. I've order some cheapo easy outs off ebay. But do they not just "unscrew" have been screwed in?? - how do they grip?

[jplautomotive 0]

Yes, I can see right through - it's simply the whole "thread" that's stuck in there. I've order some cheapo easy outs off ebay. But do they not just "unscrew" have been screwed in?? - how do they grip?

 

they are left handed the more you try to undue the tighter it grips

[EdCherry 34 1 Cars]

They are left handed thread. If you think about it you screwed the plug in to the right, these screw in the metal going left (the way you'd normally undo a bolt/nut) and will turn the existing thread the opposite way.

[BackStreetRacecars 3]

In the past I have sorted out similar problems using a left hand twist drill. Basically a normal drill but it goes the other way, So while drilling into the plug there are forces trying to unscrew it... You will have to drill it for the ez out anyway and it may just screw the remaing thread right out. Job Done.

 

Another way is if you have a welder to hand and some steel pipe. Brake pipe or similar. Weld through the middle of the pipe onto the top of the remaining plug, then weld a nut onto the pipe keep it as short as possible to reduce twist and chance of snapping it... job done again!!!

[2052006 10]

So does the easy out get drilled in using a drill / or do you do it by hand? (The hole's already there - as the electode part is already out)

[mikespug 1]

by hand would be your best bet as a drill will spin it to fast to grip

 

mike

[EdCherry 34 1 Cars]

Id say slowly on a drill personally.

[BackStreetRacecars 3]

quick thought..... does the engine run? If so you could run it up... albeit with a misfire....to get it warm and aid removal of the threaded section? You would probably be better to unplug the injector on that cylinder too to prevent unburnt fuel in the exhaust.

[dcc 855]

had this happen to a 8v engine a while ago. easy out solved it in 2 mins.

[philfingers 5]

my thoughts are if it snapped off it must be damn tight and an easy out wouldn't work. Worth a try. I think if you can't get in from the top with a MIG welder then you'll best pull the head off. Welding a rod onto the broken plug is the easiest option. It put a lot of heat in and really helps free things up. If the plug thread gets damaged you can always get it helicoiled

[2052006 10]

Well, I had to take the head off in the end. Got the plug out quite easily then. I tried an easy out, but it just wouldn't budge.

 

So new cambelt, head gasket and head bolts and all is working again.

 

Couple of questions:

 

I have a slight whine coming from somewhere on the cambelt - I backed the tensioner off a bit - and this improved it, but there is still a faint noise - does this matter much, it is very quiet now - I don't want to back the tensioner off too much.

 

Also, I put some old plugs out of a 1.9 8v into it, seems to work ok, but I've still got a slight hesitation - would this be because I should go and get some suitable plugs