working on 5.4 triton 3 valve engine, broke off 3 spark plugs, ok no problem just get out the broken plug remover, but we have a problem with the spark plug is so stuck the tool is just pulling out of the plug. we have done many, many of these broken plugs but none like this one. does anybody have anything that has worked in this situation. really hate to pull the head off but we are running out of options. like i said we have done ALOT of these plugs so please don't tell us the things like soak it overnight and it will come right out! just hoping someone has had luck getting a stuck broken plug out when the tool does get it done.

 

There are times when one tool will not work and we have to get a different tool designed for the job. I'm sure you are aware there are several tools available to overcome the problem and you just may have to use more than one of them to get it done.

 

when we talked to some ford dealer mechanics they told us our tool was wore out and we need to replace it which we did with no results. we are aware of tools from rotunda that can be used of the porcelain is not in the shield. other than the matco tool, is there an oversized puller that is available that our snap-on, mac, matco tool guys are not aware of yet? we have a number for lisle corp. engineering for possible updates that we are still waiting for a response. we are getting backed up on work and customer wants his truck back as you can figure. he wont be happy with the price if we have to r&r cylinder head to have it repaired, but we are trying everything we can to get the job done and have a customer that is satisfied with our work.

 

As you know the difficulty that comes with this type of job has some bearing on why the customer waited so long to have the plugs replaced. Most of the time it can be done with some sweat, but you can bet the dealer wouldn't have any qualms about calling the customer and informing them the heads have to be removed/replaced and the customer buys it. There are some things that just can't be avoided and head removal in this case may be one of them.

 

I've been in this business a long time, and hanky is right. You didn't design, build, or buy the truck. You're just the poor dope that gets to listen to a whining customer bitch at you while you are getting your but kicked doing a tune up.
If the customers were not made aware by now, it's a stinker for everyone involved. If they become difficult, you might tell them that the plugs come out ever so much easier at 50k (like the owners manual sugests) rather then at 100+k.
The other great point is that they changed back to a conventional design plug in '09.

 

Called Lisle Tool engineering dept. and they gave us a tip that worked. Get a 1/4" masonary bit and chuck it in a 90 degree die grinder. Grind out the porcelain that was already pushed down with the pusher tool about a 1/4". On the tool that cuts threads into the spark plug shield, grind down the shaft just behind the threads so the diameter of the shaft is slightly smaller than the the diameter of the bottom of the threads, this will allow you to thread the tool deeper into the stuck plug shield. Make sure to blow all the porcelain dust out with shop air befor you try to install the tool into the plug hole. We soaked it down with some more PB Blaster and turned the tool just enough to know that the tool turned just a little bit. let it sit for 5-10 minutes and kept doing that till we heard it "pop". Once we knew the shield was coming out, we just kept cranking on the tool. It popped and creaked all the way out, took us about an hour, but we got it. Man, the beers went down good after we got done with this job! Can't thank Lisle Tools enough for the tip! Hope this helps somebody with the same problem!

 

Thanks for sharing that addl info with us !