Broken Spark Plug Nightmare Resolved
What a stressful week. In the process of replacing spark plugs on my 2021 F150 last week, I learned a lesson - if it feels like too much torque, it probably is. I replaced 5 of 6 plugs and on the back right one I had to get a breaker bar out, and pop, out came the entire plug, minus the thread which was still in the head.
Tried several different things. I will say I was lucky that no porcelain broke off, so I only had to get the thread out.
- Flathead screwdriver into thread, no luck
- Kroil penetrant spray multiple days in a row, then round screw extractor (easy out) sizes 4 and 5, no luck.
- Called mechanics and machine shops. Set up a couple appointments, only one that gave me a rough estimate said if they had to pull the head at least $2,000. Yikes.
- Between that time and the appointments, I ordered a specially designed spark plug extractor from amazon (Amazon.com: ZKTOOL 8~12MM Universal Broken Spark Plug Removal Kit, Broken Wire Extractor, Reverse Thread Tap, Thread Tap Extractor Set Reverse Cone, Used for Removing Stuck or Damaged Spark Plugs,With 12mm Socket : Automotive)
This ended up being the silver bullet. I was skeptical it would be any different than the screw extractor, but it was a perfect fit, and even more importantly, it was a hex shape to fit a normal socket, unlike the square headed screw extractors which were a loose fit with the tools I devised.
Some serious downward pressure and VERY slow turning, along with one last shot of Kroil, and the spark plug extractor bit and pulled the plug thread out.
I wasn't too concerned about debris in the cylinder because there was no porcelain involved, but I did my best with compressed air to blow it out. Finally got the new spark plug in after a week of trial and error. Just know that if you have this issue, it is NOT a complete lost cause.
In the process I broke my oil dipstick, which was another job for afterwards, but we are back in service now, and the 2.7 (which I love) continues to run like a champ!