Broken Spark Plug in Head

[mhouston44]

I've got a 2004 SANTE and I was changing the spark plugs and one broke off in the head. I tried using an EZOut with no success (it broke off insidge the spark plug). Has anyone ever pulled the heads off before, if so, how bad is it? Has anyone had to have someone take the heads off for them, if so, about how much did it cost?

Thanks for any help......

Gotta get this done so I'm operational by the time it warms up.

[ski4evr]

I have had some success with a set of reverse drill bits in you situation. Never on a spark plug, but with exhaust manifold bolts broken off in the head. Spend some time soaking with penetrating oil to try to break the grip of the corrosion first by soaking every day for a week. The ezyout will be hardened steel, so the bits will have to be good quality and a low speed drill will have to be used with lubricant on the bit to prevent heating. Many times, the bolt backed out with the reverse bit without having to get the extractor involved. Might save dismantling the engine. Good luck.

[2gofaster]

I have managed to get out spark plugs before using a small cold chisel. Spray penetrating oil around the threads repeatedly and let soak overnight. Then take your cold chisel and tap a groove into the steel shell. You can then lay the chisel back over at a lesser angle and use small taps of the hammer on it to try and rotate the shell out.

[TRDon]

dont forget, if you do get it out with the head on, look really carefully at the piston side of the plug and make sure it is all there. If you are missing anything (ground strap, any porcelean) pull the head and clean it out of the cylander. If you dont, you may destroy the wall, head, piston.

[xrichard]

you might have metal shavings on top of the spark plug by the time you use a chisel or extractor on it. If you get it free and it's coming out, before you unscrew all the threads, you should vacuum around the plug. I've used a small tube as an extension duct-taped to the hose on a shop vac....it'll clear out any debris that might otherwise fall into the cylinder. If you're missing anything on the other side of the plug, you can clean out the shop vac canister so it's pristine, then use the rubber tube to stick down into the cylinder and try to get whatever is missing (e.g. electrode, small piece of ceramic insulation)....then verify you got it by taking a look in your shop vac....that's why you want the canister perfectly clean.

[mhouston44]

Thanks for all the advice guys...........I decided to go ahead an take it to my regular service shop. Too many opportunities to mess this up worse.

[obd666]

prolly not a bad idea at this point, would be easy to make a bigger mess from here. good luck and let us know how it turns out