I'm guessing the "new" truck I picked up has been sitting for at least a year.

When I tired to change plugs today, I had to use a touch of PB Blaster and air just to clean the crud off the tops of my plugs just so I could get a socket on the hex.

I started on the right bank and none of the plugs would budge. I let the truck warm up to op speed, applied a little more PB and nothing would budge. Finally, against everything I learned about old plugs, I used a lever to try to back out one of the plugs a 1/4 turn so I could let PB Blaster soak overnight and the plug broke loose, leaving the bottom stuck in the head.

I know there's a Miller Tool for the '04-'07 F150s they use to get the bottom out of the head. it's kind of like a tap tool.

Is there anything out there for my 5.9L to help me get the rest of the plugs out if they break? I limped my truck to a local mech to get the one plug out and told them to call me if they think it's going to be a problem with the other plugs. If I'm looking at a $400-$500 plug change, I'll let them do the one I broke and try again on the other.

Any tips on how to loosen them up so I can start to apply PB to the plugs?

Has anyone tried running Seafoam through the fuel system to loosen up the carbon build up?

Feel free to chime in if anyone has any ideas how to get these old plugs out.

Thanks!

 

Is it broken off flush or do you still have the hex ? and yes alot of us use seafoam, works good

 

Just a good old easy out is about all there is. Snap-on makes a nice set, but the kind you find in your local mom and pop store will work too. Have you tried holding moderate pressure on your ratchet with one hand and hitting the end to shock the plug with the other? This action works a lot like an impact and jars the plug loose. Fact is, a 3/8" impact turned down so it won`t immediately snap the plug will work wonders. Just let it chatter for a little while and eventually the plug will come out.

 

Thanks guys. Yeah, I'm leaning toward a good soak overnight with PB, after a Seafoam treatment on the rest. EZ-out seems like the best way to go. I've never had to use one since I tend to check plugs often and I use anti-seize.

What the best way to proceed with the EZ-Out?

 

Forgot to add, the hex came out with the plug. Original plug. It was so rusty, the hex actually slipped off the plug when I pulled it out (after breaking off). I'm not sure since I got the truck at an auction, but I think it's been sitting for at least a year.

Ran great (until I broke the plug). Tranny and 4X4 works perfect too. 88K miles. All I added was a drag link, steering damper and a new Class III hitch. $2200

 

i have the same problem. did you ever come up witha solution? i tried using an easy out but the piece i bought from an auto parts store broke in there so now i have the threads off the spark plug with an easy out broekn in there too. i'll take the head off if i need to and dig it out and helicoil it but i dont really want to. did you figure it out?

 

If you can get a good angle at it, put a center punch on the easy out, and see if you can shatter it. (keep in mind, you more than likely will end up with pieces in the cylinder.... more on that in a bit) Once you have it out, soak what's left of the plug with chemicals. (PB blaster, freeze off, whatever.) Do that several times over the course of an hour or three, and then try with a better quality easy out. Don't reef on it to hard, just steady pressure......

I have also had plugs I had to use a small chisel to cut them out.... that was fun.....

Once you have everything out of the plug hole, leave the hole open, and crank the motor for 30 seconds or so, a couple times. (this should expel anything that got in there.)

Put your new plug in, hook up the wire, and start the engine. If you hear any odd ticking noises...... pull the plug back out, disconnect the injector on that cylinder, and start the engine again. That should convince anything that's left in there that it REALLY wants to come out.

Put it all back together. Should be golden.

If you really can't get the stuff out of the hole. Yank the head. I would have a long hard look at replacing them both if you have the scratch. You can get better-than-factory replacements for under 300 a pop on ebay.