97 XLT 2nd plug on drivers side. I replaced plugs and wires a wile back and this one was sticking so I left it. Last time I had the oil changed at a shop and asked them to look at it. He told me I was looking at several hundred bucks and it needed to go to the Ford shop. I later looked at the plug and evidently thay had tried to remove it and in the process severely rounded it. I do not want to yank the head as I am cash strapped right now. I have two ideas. The first is a helicoil - anyone use one? Second was to JB weld a socket onto the plug and try it that way after first using lots of penetrating oil to the threads. Someone please help!

 

yeh sounds like jb weld or epoxy is ur best option. or try removing it while the engine is hot.

 

Break the porcelain off, vacuum/blow out all the flakes, then use a spiral-hex extractor socket. Sears & all the tool trucks carry them.

 

Damn !! what's holding it in there? Well , the easy out sounds like a good plan .. Good Luck

 

Depending on the age of the engine and your comfort level working with the engine, it may be easier just to take it in to a professional. While the JB weld in the socket idea COULD work, what happens if it doesn't? Now you've got a spark plug and a socket that is stuck to it and your vehicle is completely stuck. Or, depending on how old the spark plug is, just leave it until either the vehicle dies, or it absolutely HAS to be replaced, then figure out something then.

 

yeh breaking off the porcelin and easy out could work. if not then drill out the center of the plug and cram a big flat blade screw driver down in there and then try to back it out.

 

my guess is, if a 6-point socket can't loosen the spark plug, a screwdriver won't do much better, but who knows.

 

Doesnt sears have a socket that fits rounded nuts? Seems I saw one, but the socket diameter may not fit in the hole....Sounds like the easy out is the best bet...good luck

 

Pick a metric socket that is just too small to fit. Smash it on with hammer and an extension and it will come out. I've done this before. You maybe even get lucky and be able to get the plug out of the socket later. If not you're just out of a socket.
The other route would be to use the special sockets from sears. They are expensive though.

 

seats has the "bolt outs" they are greay but.. they are wider where the ratchet goes on so...might not fit in there. ive seen them on sale for 12.99 for a set of 5. worth it in my opinion.

 

A little PB Blaster on the gasket may help.
I like the slightly undersize sacrificial socket approach.
I have used it in the past.
The shock of driving on the socket can help crack the threads loose.

Take your time – if the first attempt fails, the second has less chance of working.

 

At worst, you'll be doing this:

http://www.supermotors.net/vehicles/.../15812/53268-4