Well I am in the process of installing my Roush charger. I needed to pull the plugs to change them with the ones provided in the kit. I followed the instructions on the TSB for plug removal except that I used PB blaster instead of kroil. Well the first 7 plugs came out with no problems just a little creeking but I will be damned the last plug broke on me at least it was plug number 1 all the way in the front. Well this plug broke and the only part that came out was the threads. All of the porcelin was left in the head, I took long nose locking plyers and was able to get most of the insulator out, it still left the lower insulator in the electrode. Well now it was time for a couple of to think this through. I tried turning the motor over but wouldnt, you know it doesnt work with out the PCM(since I sent it to Roush) so I had to crawl under the truck and jump the starter by hand, didnt even budge the insulator. Now I am still trying to figure this out and my wife says why dont you try breaking up the insulator. So I stick a phillips screw driver in the hole and start taping on it with a hammer(not much choices left at this time) well I get a lot of the insulator broken up to at least put a tap in there. So I tap the ground electrode with a 3/8-24 tap and while tapping it breaks loose and starts spinning. So I pull the tap out and insert a 7" long spring clamp bolt with 2 washers and a spacer and a jam nut in. The first washer sits perfectly in the opening in the head on the little lip and a couple seconds later the electrode is pulled free. I did notice that a small piece of the insulator broke off the tip and landed int eh cylinder, so I get my vacuum out with a piece of hose and an old bic pen body and sucked it up out of the cylinder( man was I lucky). any way just to let yall know there can be a happy ending with the plug being broken. Also for those who want to know the truck is a 04 5.4l with 52000 miles on it. here are a couple of pics.

looking down in the spark plug hole. you can just make out the insulator at the bottom.

homemade electrode removal tool.

 

Way to save a bad situation!

Nice write up and very good pictures.

Maybe this post will help others when it happens.







Chris


My 4.6 with the non-creaky, breaky plugs never looked so good.

 

Wow....... You have my kind of luck. I can't count the number times I have been that situation. It should have been easy!!! I tell my wife as the kids run for cover!

Way to think it through and get it done. Those are the times when having as many tools in your shop as possible helps.

 

Good job! Way to Git 'er done! It's still something that we shouldn't have to deal with though.

 

Fine recovery job. It's always rewarding to DIY yourself out of a jam. Now you can concentrate on the roush!