Changing plugs in 2.7, plug broke off

Yes it broke off just like you are saying, but the nutted end came with it. The only thing left is the threads and the hook on the end of the plug. It actually made getting the extractor on there easy, now the extractor doesn't want to turn it.

I let it soak last night again and I am going to try it again today. We will see how it goes, I can't complain too much with this many miles and no issues before.

The truck may have had a valve issue anyway, I was doing this because of a low rpm miss so I dont even know if the plugs or wires would have fixed it.

We will go back to the drawing board if the extractor breaks off, the head may be coming at that point.

 

The 3V 4.6 Fords were notorious for breaking their 2 piece spark plugs. Lisle makes a tool for broken plug removal, you might want to look into it to see if it would help you here. The tool is around $70-$80 and can be had at any auto parts store. Looks like this:

 

Ahh ok got it... 1 question, did you have to turn the EZ out left to thread into where it's at? Reason I ask is you may have a "right turn" extractor (for reverse thread apps.) In any event it's not uncommon that they get tight when they feel like they should be loosening up, if just threads sooner or later they're going to collapse & you'll get it out but you may have to heli-coil the plug hole..

 

Have had to deal with this a few times on various engines. The most recent attempt I used a square shaped easyout, penetrating oil and a butterfly impact wrench. I've had an easyout break before and that's game over. So by using the impact wrench I felt like there was little chance of breaking the easyout and the light hammering effect of the butterfly impact wrench helped get the penetrating oil to do it's job. I worked it a little, added penetrant then came back and hit it with the impact again and so on. After a few cycles it came out. The square easyout let's you use the rattle gun in either direction.

 

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Thats the ticket....

 

Just keep in mind the easyout is very hard and therefor brittle. You want to set the rattle gun towards the minimum setting.

 

I made sure this easy out was threading correctly before I started, it threaded in by going counter clockwise which is what I want.

I am using a 3/8ths drive extension to go on the extractor and it is now rounding on the extractor head. What is the best thing to use to attach to the extractor head?

I have an impact gun I may try that, good idea

 

Problem now is the head of the extractor is rounded off. a 7/16ths star socket would turn it before as well as the female end of a 3/8th extension. Now both of those have rounded the extractor. Also a 10mm star socket was rounded as well. It is getting smaller.

Anything you guys know I could use to get a tight fit on this extractor so I can turn it?

 

Well, the valve cover will have to come off and that spark plug tube will have to be removed, then you should have enough room to be able to get something on the extractor.

 

Pull the head and machine shop time...

 

I feel for ya brother. You're falling deeper and deeper down the rabbit hole. If you can get that extractor out you may still have a chance to avoid removing the head. The bad thing about the theaded tapered extractors is that as you apply turning force you are also expanding the surrounding material. Although the square extractor is also tapered it only contacts at four points and when you hammer it in it helps release the chemical bond. It's actually making the round hole a little bit square which should help release the external threads from the internal threads. Something else to try. Heat works wonders on stuck fasteners but how can you get it hot without collateral damage. The answer is friction. Select a drill bit that is a little bigger than the hole you're working in and spin it in the wrong direction while applying a lot of downward pressure. When it gets really hot spray it with the penetrant. Now insert the extractor. If it doesn't move use more heat and more penetrant.

 

Can you put up a link or detailed picture of the extractor you used?.

 

Well I have given up on it for now. I will more than likely be removing the head. I had to use a spiral easy out because I could not find a square one anywhere.

Thanks for all of the help guys I appreciate it. I hate that after 337k miles a stupid broken spark plug is causing me to have to do major work to the engine...

 

Ok, spiral cut ez out.. gotcha.

Valve cover off, spark plug tube removed, Vice grips clamped to the extractor, 2 or 3 external leg adapter on a slide hammer, slide hammer legs grabbing the side clamped vice grips,,tap tap tap with the slide hammer. It should pop out. It might take a couple resets of the tools as you go.

Edit: Or pull the head for full rebuild, just seen your miles.

 

With the valve cover off and the spark plug tube remove is it possible to weld a socket to the top of the extractor?

 

Excuse my ignorance, but how does the spark plug tube come out - do you just yank it out?

 

I'm pretty sure they screw out. The similar ones on my Camry screwed out - never taken them off on my Tacoma.

 

Makes sense. I stupidly though they were part of the head, but that wouldn't be a good design.

Absolutely OP, pull the valve cover and tube and you will have a lot more room to work with. You'll get this thing without pulling the head.

 

You can also try a broken bolt extractor or "swirl" socket on the easy out but that would be my last resort.

 

Yes the swirl socket has stripped over top of the extractor. The head will be coming off, thanks for all of the help guys