I have a Dodge 1500 and am unable to get 3 of the plugs out. The holes are rusting closed around the base of the plug, so I cant get a socket on them. I"ve been spraying them with PB Blaster daily and trying to scrape the rust away. I removed the shields from 2 of the plugs. I was thinking about using some sort of dremel attachment to get down in there and grind it out. I'm at a loss!!

 

Might sound kind of dumb but I would try the dremel thing or take a thin flathead and lightly tap at the base just enough to let the pb soak in try and tighten them to. Anything to get the pb in there and break them free. Maybe somebody has a better suggestion though. Never been in that situation personally

 

Yeah, pull the heat shields, and blow as much of the crap out from around the plug base as you can. If you have to, use a pointy object to scrape it out. use a real spark plug socket, and if you have to, tap it on to the plug. Liberal use of chemicals is also highly recommended.

 

Wouldnt it be bad to get rust and pb blaster down there?

 

If the spark plug is still there, it isn't going to get inside. The idea is to remove as much as you possibly can, so that it DOESN'T get into the cylinder.

 

If any gets into the hole when you pull the old plug, just pull out the fuel system relay from the PDC and crank the engine over a few times without a new plug in it.

99% of anything that went in the cylinder will shoot right out of the plug hole.

 

Compressed air is a must do first, whether or not the heat shields are in place.

 

Exactly my first thought. I love having compressed air available; I have three quick-connects on the regulated side of my shop compressor, and two on the unregulated side so I can blast stuff with 165 PSI when I need to. Even that might not budge the crap you're trying to get rid of, but it couldn't hurt.

At a bare minimum, I think anyone who works on his own vehicle should have a portable air tank, so at least you can have limited bursts of 120 PSI air. Definitely the way to go for cleaning out those spark plugs recesses and a million other things.

Here's another thing you might try. I often modify sockets and wrenches to perform a certain task. You might want to try grinding a nice 60-degree or so cutting edge onto a spark plug socket and smacking it home with the basher of your choice. The cutting edge might allow the socket to get down far enough to get a good grip on the plugs..

 

So after all the pB Blaster soaking and compressed air and digging, 2 of the plugs snapped off. I cant get a drill in there to get the # 5 plug out. Is there any documentation anywhere with some pics on removing the head? Or do I have other options?

 

That one is in rather a fun location..... did you pull the heatshields? Get better access that way. Gotta be careful with drilling them out though, can't leave ANY metal shavings in the cylinder.