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  #1  
Old 11-10-2008, 10:13 AM
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New method to extract porcelain from broken spark plugs

Changed my plugs this week, three broke and two left the porcelain in the head. To get them out I used a method that I haven't seen described anywhere that worked really well.

I used a #2-56 screw glued into a 2" #4-40 standoff as the "pin" to glue into the porcelain. For the "extractor," I drilled and tapped a #4-40 hole in the end of a 3/8" threaded rod and put a #4-40 screw in it. Essentially it was a threaded rod with a smaller threaded rod sticking out of one end. The extractor then screws into the end of the standoff part of the "pin." You use the same method to extract the porcelain as you would the ground shield with a threaded rod (described in this thread). The pins are sacrificial, but the extractor can be used over and over. It worked like a champ. Also, you can use the other end of the rod to extract the ground shield.

And if there's any interest, I could build more and sell them for a small fee.


Here are two of the "pins." The top one has porcelain attached. The bottom is unused.
Click the image to open in full size.

Here is the "extractor." The right side is the tip, with #4-40 screw.
Click the image to open in full size.

Here's an up close picture of the extractor tip.
Click the image to open in full size.

Finally, here's an unused pin threaded to the extractor.
Click the image to open in full size.

Last edited by vtron; 11-10-2008 at 05:57 PM.
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  #2  
Old 11-10-2008, 10:16 AM
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seeing what a pain in the butt it is to change plugs out I wonder if it would be worth it to have a mechanic do it.. and do you really think a mechanic would change all of them out ?? I am to scared to touch mine, (5.4 v8) heck I cant even see them..
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  #3  
Old 11-10-2008, 10:48 AM
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Could you please post some pics of your tool, sounds very interesting. how hard was it to pull out the porcelain using your tool?
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  #4  
Old 11-10-2008, 11:12 AM
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It was really easy once the glue set up. I made the mistake the first time of not letting the Motorcraft carb cleaner dry before gluing the pin. The glue never set and it pulled right out of the porcelain. Once the cleaner dried and the glue cured, a few turns of the nut and the porcelain pulled right out. Hardest part was putting the pin in the hole and trying not to touch the sides.

I'll post picks tonight when I get home.

By the way, I used Locktite 444.
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  #5  
Old 11-10-2008, 06:02 PM
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Now with pictures.
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  #6  
Old 11-10-2008, 06:05 PM
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Quote:
Originally Posted by FX4_2003 View Post
seeing what a pain in the butt it is to change plugs out I wonder if it would be worth it to have a mechanic do it.. and do you really think a mechanic would change all of them out ?? I am to scared to touch mine, (5.4 v8) heck I cant even see them..
What year is your truck?
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  #7  
Old 11-10-2008, 07:07 PM
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QUOTE=bluejay432000;3448199]What year is your truck?[/QUOTE]I read the wrong post

Last edited by RUSS04; 11-10-2008 at 07:42 PM.
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  #8  
Old 11-10-2008, 07:13 PM
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Quote:
Originally Posted by vtron View Post
Changed my plugs this week, three broke and two left the porcelain in the head. To get them out I used a method that I haven't seen described anywhere that worked really well.

I used a #2-56 screw glued into a 2" #4-40 standoff as the "pin" to glue into the porcelain. For the "extractor," I drilled and tapped a #4-40 hole in the end of a 3/8" threaded rod and put a #4-40 screw in it. Essentially it was a threaded rod with a smaller threaded rod sticking out of one end. The extractor then screws into the end of the standoff part of the "pin." You use the same method to extract the porcelain as you would the ground shield with a threaded rod (described in this thread). The pins are sacrificial, but the extractor can be used over and over. It worked like a champ. Also, you can use the other end of the rod to extract the ground shield.

And if there's any interest, I could build more and sell them for a small fee.


Here are two of the "pins." The top one has porcelain attached. The bottom is unused.
Click the image to open in full size.

Here is the "extractor." The right side is the tip, with #4-40 screw.
Click the image to open in full size.

Here's an up close picture of the extractor tip.
Click the image to open in full size.

Finally, here's an unused pin threaded to the extractor.
Click the image to open in full size.
Good infoHow many miles on the motor when you changed them ?
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  #9  
Old 11-10-2008, 07:15 PM
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Do late model 06 have the same plugs too?
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  #10  
Old 11-10-2008, 07:31 PM
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Quote:
Originally Posted by 06 SANDSTONE View Post
Do late model 06 have the same plugs too?
Yes they do have the same plugs
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  #11  
Old 11-10-2008, 07:36 PM
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Nice work
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  #12  
Old 11-10-2008, 07:48 PM
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Quote:
Originally Posted by FX4_2003 View Post
seeing what a pain in the butt it is to change plugs out I wonder if it would be worth it to have a mechanic do it.. and do you really think a mechanic would change all of them out ?? I am to scared to touch mine, (5.4 v8) heck I cant even see them..
If you have a 2003 You do not have the plug problem
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  #13  
Old 11-10-2008, 08:31 PM
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Quote:
Originally Posted by RUSS04 View Post
Good infoHow many miles on the motor when you changed them ?
I had about 45,000 miles. First 3 plugs broke, two with the porcelain inside. The last 5 came out clean.
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  #14  
Old 11-10-2008, 09:25 PM
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Quote:
Originally Posted by vtron View Post
I had about 45,000 miles. First 3 plugs broke, two with the porcelain inside. The last 5 came out clean.
Iam happy you got them out on your own Its sad that you had to go through all of that just to change plugs Ford knows that there is an issue with the plugs But they dont care
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  #15  
Old 11-12-2008, 01:38 PM
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Great information, vtron!!!
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Old 11-12-2008, 01:38 PM


 
 
 
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