See full version: How to remove a broken spark plug embedded deep down in the engine block
My trustee Toyota runs great for an old car. I have had it for about 9 years now and it is in good shape. Every two years I have to summit it for emission testing in the state where I live. Two years went fast and I need to take my car for an emission test this year before I can renew my registration.
I asked some people and everybody had their own idea what I should do but, no one came up with a solid answer. I went to the mechanics and they wanted from $450.00 to $1200.00 to do the work and still it is not guaranteed my car will pass. I decided to Google around and I was overwhelmed with the thousands of results. After a while of sifting through the google jungle I found some hints. It looks like I have to change my car’s spark plugs, so I bought the best spark plugs I can get. The next day my friends and I started changing the spark plugs and when we were changing the last one it broke almost in half. That was a disastrous and costly mistake with no easy solution. [links]
I took it down to the emission testing center but it failed. I knew it wouldn’t pass the first time because the car was way past due for a much needed tune up. So, it wasn’t a big deal when the testing technician told me my car didn’t pass. I knew he would not give me any meaningful advice but I asked him what he thought I should do to get it to pass the emission. His reply was predictable: "sir, I can’t tell you what to do we are not allowed to give out advice; however a general tune up would help you" he said. I said to myself, he is right I will change the oil, the air filter, put premium gas and bring it back. I did all that and took it back but, the car failed for the second time. This time, I was really worried what to do with the car to pass the emission. more
My car now is completely disabled leaving me with no transportation. I went back to the mechanics and they said it will cost me from $1800.00 to $2000.00 dollars to fix it. When I asked why is it so expensive? The lead mechanic said “because we have to take down the head of the engine block, tap out the broken spark plug, install a new head gasket and ……. blah blah blah he kept going on and on making a long list of things that needed to be done. My car is worth about $2800.00, how would I spend that amount of money to fix an old car?
Don’t think a 30-min soaking is going to let you zip the spark plug right out of the head. It won’t. But it will let you move the plug 1/8 to ¼ turn, and that’s what you want. Place the spark plug socket on the plug and try to turn it out by ¼ turn. If it still won’t budge, try tightening it ¼ turn. The whole point of this exercise is to move the threads enough so the rust penetrant can wick into the threads. Once the plug turns, add more rust penetrating oil. Continue turning until you meet resistance. Then STOP and add more penetrating oil. more
Clean the spark plug threads in the cylinder to remove as much rust penetrant as possible. Use a dry rag to soak up the oil. Then spray the seat and threads with brake cleaner to remove all traces of the oil. [links]
With longer spark plug life it’s not uncommon to run into a stuck spark plug. But if you exert mega force to remove a stuck spark plug, you can also shear off the threads in the aluminum cylinder head, and that’s a MAJOR repair. Removing a stuck spark plug without damaging the cylinder head takes time and patience. Screw this up and you’ll be in a world of hurt with a repair bill upwards of $500 to $1,200. To take it SLOWLY and follow these step by step directions to remove a stuck spark plug.
I know this doesn’t make sense, but tighten the spark plug until it seats. Add more penetrating oil. here
You must have the proper tools. We do not recommend a “spiral-cut” (Figure 1) type of easy-out; rather we recommend a “square-cut” (Figure 2) type design. A spiral cut design has a greater potential of causing the shell to expand, locking even tighter to the cylinder head as removal pressure is applied. more
Although the required installation torque on taper seat spark plugs is only 7 to 15 foot pound, we have heard reports of successfully removed spark plugs, without head damage, at torque values exceeding 180 foot pounds! [links]
Let's say you are working on a simple tune-up and during spark plug removal, one breaks off below the hex, leaving the threaded "shell" stuck fast in the head. That can happen with any spark plug but most frequently with the smaller 5/8" hex size. It may never happen to you, but if it does, don't panic. You're probably asking what caused it and how do you get the broken piece removed without pulling the head.
On the other hand, the square cut type with its sharp flute will dig into the shell metal to provide a strong gripping surface without expanding shell metal. here
This article was co-authored by Mike Parra. Mike Parra is a Master Mechanic in Arizona. He is ASE (Automotive Service Excellence) certified, has an AA degree in Automotive Repair Technology, and has over 20 years of mechanic experience. more
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Spark plugs make a gasoline engine run by shooting sparks into and igniting the mixture of air and gas in the engine's cylinders, causing the cylinders' pistons to move down and create the power that runs the car. After a while, spark plugs wear down and need to be replaced. Unlike most car repairs, replacing your own spark plugs does not require any special tools or expertise. Read on to learn how to replace your plugs and have your engine running more smoothly in no time.