After following the TSB to a "T" and after 96,000 original miles on my factory plugs, 1 broke off in the head when trying to remove them. I guess it could have been worse. I used the Motorcraft Carb Cleaner and let it sit overnight after breaking the spark plugs free a quarter turn. I honestly think the spark plug broke during the first quarter turn. If the plug is seized in the head so bad, that when you turn it the initial 1/4 turn the tip wont move, it will break. There is no way that the carb cleaner can do its job and get past the threads and tapered spark plug seat unless you get the plug to turn that first quarter turn.

Now I'm going to have to follow the rest of the TSB and try to extract the broken tip. Wish me luck. Luckily, I have other vehicles, so this car can sit until I can get the tools to extract the plug.


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good luck...although i think
you'll get it out without to
much difficulty

thanks for that pic, that's the first time
i have seen the broken plug

 

You can't grab the grounding strap with a long pair of needle nose pliers? I bet I could fab something up to get it out.

 

Big question, did the porcelain stay in the ground shield, like mine did, or did it come out with the plug leaving the empty shield? What kind of plugs are you going to put back in? I agree with you, I think the damage occurs in that first 1/4 turn.
Best of luck from somebody whose been where you are. I feel your pain.

 

Yes. The porcelain is still in the ground shield. I'm soaking it in PB Blaster...gonna let it sit over night and turn the motor over with the injector and coil for that cylinder disconnected. Hopefully the compression will pop it out like a cork. I've heard some F150 guys have used this method successfully.

 

Ugh. I was all set to do mine tomorrrow after reading several success stories, but now you have me nervous again. I only have 25K miles, but it's my daily driver so I'm screwed if I break one. Guess I'll just see how I feel tomorrow morning.

 

this is unbelievable

 

Man you guys got me freakin out now, lol wtf.
Champion I guess has a one piece plug......

 

I tried the cork method, and it worked to pop the ceramic out. Well, actually, I had to run the car on 7 cylinders (well 6 actually because it turns out I half-broke another plug getting them out) and once the engine got warm enough it shot out. I used a Craftsman easy-out to get the metal sheath out. All good after that!

 

16,000 miles, and my plugs came out with less then 20lb-ft of torque.

Good luck with your plug removal. Sounds like you have patience, which I think is required at this point!