how to remove stuck spark plug from aluminum head?

[dtt454]

so, let me share my story. its a quad 4, please spare us all and lets not discuss how good/bad the engine is to start with.

anyways it was getting coolant in the engine oil, its been this way for a while, as far as i know it never hydrolocked. anyways i got the head off (the head is aluminum) i was trying to take the spark plugs out, 3 come out fine, the 4th one is stuck.. and i mean stuck good. i was trying to use a breaker bar and i stopped because, sometimes you get that feeling if you pull any harder something is going to break, ill fly backwards and land in a pile of engine parts. so i stop and think since its off anyways wouldnt it be nice to figure out a way to get it out without destroying the threads..


so for now i got the head sitting out there upside down with penetrating oil soaking it, but if anyone has any other suggestions im open to ideas.

the spark plug does not look damaged so i have reason to believe its just stuck from age/corrosion/ maybe having coolant in there, but not from mechanical damage.


my only other idea was to put the head in the oven and heat it a bit, then try to use something to cool the spark plug quickly while leaving the head warm. but before i smell up my house by sticking the head in the oven i thought id see if anyone has any other suggestions.

 

[tdkkart]

BBQ grill

 

[dtt454]

and please dont tell me "should have used anti seize" i know this, it will get it in the future im just concerned right now about getting it out.

 

[dtt454]

actually i never thought of the grill, i have a smoker that would work even better

 

[wornoutoldman]

After 24 hrs you may want to flip it over and soak the other side. Have an impact gun? I'd use the shortest extension possible on a 1/2 drive extension and give it a couple of short bursts. Good Luck! Let us know how it turns out.

 

[Garage5.9]

Im surprised the cermaic part didn't brake off yet. seen that a few times and its a real PITA to remove with out taking off the head.

 

[boogerboy72]

1/2 inch gun, if that dosnt work, 3/4 inch, and so on. if it tears up it tears up.

 

[Lincolncruiser95]

Try heating just the head...apply a socket to work as a heat sink of sorts and go at the head with a heat gun or propane torch set low. If that doesn't work, heat both together then get yourself some canned air. Turn the can upside-down and spray the plug from top and bottom. May take a couple cycles, but that should help break the weld created by metal to metal contact of differing materials. I've done this to many a bolt on old cars. The freezing cold propellant does wonders ;-)

 

[theoldwizard1]

When you get it out, if the thread need to be repaired, use a Timesert instead of a Helicoil.

 

[Brianw]

Take the head to a machine shop. It might cost you $10-$20 for them to get it out but they will probably do a good job. I have worked at a machine shop for many years and have seen and fixed all kinds of stuff like this. Besides, it probably needs to be checked for cracks and then if ok milled and lapped to a smooth finish. The quad 4 cyl head requires a very smooth finish for the gasket to seal properly. You have the head off already, so why not do it right?

 

[srmofo]

The good news is the head is already off, so a trip to the machine shop to fix it wont turn that job into a PITA. Other than that all the other suggestions sound good

 

[slopecarver]

I was actually gonna suggest the canned air. try tightening the plug too, then remove as normal

 

[stevefasano]

removed due to

 

[metalhead212121]

Put the head in a freezer like 2 days...then when you pull it out,heat the head with the torch for a minute or less and fast get the plug out..I did it twice and it works...third time the plug came with the aluminum threads...don't let the plug get warm..
Good luck

thats a pretty good idea... never thought of that.

 

[REAL HOT SCHITT]

Spray kero in affected area then undo plug by gion back and forward untill undone, then tap out with vacume cleaner sucking **** out (if head still installed on motor) and insert stainless thead insert to suit....the local diesel injector pump service shop shold have rite inserts.

 

[MoToys]

Matco and lisle both make tools for this as it is a common issue with ford v8s

 

[z28snksknr]

Give the plug a few solid raps with a hammer from both sides. That may jostle it free to where a breaker bar will budge it.

 

[nunan0219]

just bring it to a machine shop since you have the head off. they'll get it out faster than you can more than likely, and if the threads are messed up they'll repair it correctly. 20$ investment would be worth the aggrivation IMO

 

[nehog]

X2 on the impact wrench. I find they get things out with less breakage than a breaker bar does. The short impacts allow the things to go back to a static position which lessens the long term torque on the item in question.

As mentioned, no extension or a minimal extension is best. Anything in line with the item will reduce the impact torque substantially.

 

[1320stang]

Tighten before loosening.

 

[35mastr]

Head is already off. You mention you had a coolant leak which is all too common in quad 4's. Take it to the machine shop. Have them pull the plug,magniflux it, pressure test,resurface both the head surface and the exhaust and have a 3 angle valve job done.

Then you will know what you will have when you put it back together.
Reman heads are also pretty reasonable.

 

[dtt454]

so i read the freezer thing, maybe i should have tried that,

so here is what happend today, its been soaking all night, well i got me some of that freeze and release http://www.loctitefreezeandrelease.com/

shot it real good with like half a can of that (the stuff smells like toothpaste too) but working back and forth with a breaker bar it started turning a little and i worked it out back and forth over about 10 minutes it came out. but not all the threads are in good shape, although there is still enough threads in there another spark plug will grip and torque, i think id rather insert it while its off rather than make another nightmare later. i suppose off to the machine shop ill go now. i know i could have let them do it, i kind of like knowing how to do things myself too though.

in hindsight i think i would have hung it in the smoker box and heated the thing to maybe 200 then shot it with the freeze and release to try to shrink the plug. im not really sold on that freeze and release product so far though, im sure it helped.

 

[BillK]

Dt,
Glad you got it out ok so this reply is too late, but figured I would throw my method out there. I take the torch out and hit just the plug from the combustion chamber side. Heat it real fast and red hot. Then let it cool and it will usually come right out. Same method we use to remove pipe plugs from oil galleys etc.

By the way, some of you guys must have some very poor machinists, I wont touch a broken plug for less than $50

 

[toolman1967]

Lots of great advise, nothing to add here other than a tip if the threads come out with the plug. I know lots of guys insist on helicoils, but I use a steel insert that you can buy at O'Reily and other parts stores. Just drill and tap the old plug hole and install these with locktite. I used to use these on Harley heads and have never had a failure even with nitrous and High Comp heads. Good luck.