I'm ashamed and embarrassed to write this 😞

I was getting a misfire on cylinder 5 around 45-50 mph, so I ordered new plugs and COPs. Plugs were Motorcraft, about 5 years old, with appx 25K miles. I changed the COPs and the condition remained.

I pulled cylinder 5 first and noticed the bracket to the electrode had been completely broken off (bottom left plug pictured). I'm almost positive it didn't happen during removal and it worked fine after replacement. I blew out the cylinder and used a magnet to be sure.

Now for the bad news.... I was working on cylinder 3 and I crossthreaded during removal 😫 I always take extra time during install and didn't think removal was an issue but I've learned my lesson. Anyway, it's stuck in there and I didn't try to force it out too much. When I drove after the other were all changed, it had plenty of power but did give me some misfires around 20-25mph. They were so light it was unnoticeable, I just picked it up via the Torque app. I'm also not positive this was from that cylinder but I have reason to believe that is the case.

Here's the question - should I leave it as it or try to get it out of there. If I do, who has recommendations on a good procedure. I've read about thread chasers and helicoils but I've never used either.

What would yall do - please help! 🙏

 

There's no such thing as cross threading a part during removal. Seems more likely the spark plug broke, like maybe the hex part is just spinning ?
Look up the lisle spark plug removal kit for the 5.4 as that's probably what you need if you can't get it out any other way, but you need to get the ceramic part out before using the tool as far as I know.

 

Unless you really put excessive torque on the plug I doubt the threads are striped

You may get different answers but this is what I would do. This assumes you actually were able to turn the spark plug a turn or two while trying to remove. Loosen the plug a turn or two and then spray some PB NutBlaster in the threaded area and let it soak for 30 minutes then tighten, loosen, tighten, loosen tighten, loosen. Spray a little more PB NutBlaster in the threaded area and let it soak for 30 minutes then tighten, loosen, tighten, loosen tighten, loosen. Once you get things moving change to WD-40 n the threaded area and then tighten, loosen, tighten, loosen tighten, loosen. Don't use excessive fluid just get it wet.

 

That's what I thought as well. I didn't think it was possible but I'm pretty sure I managed to do it. I was using the swivel magnet socket and I may not have had it seated properly, but I was being pretty careful.

I've also wondered it it was broken as well but the symptoms don't really seem like it. It won't move except with quite a bit of pressure. Difficult to go in or out right now. Truck still runs so I'm trying to do my research before I make it worse.

 

@Jimboy this is actually exactly what I was hoping to try to do.

Any recommendations for cold or warm engine. Seems I've heard arguments for both. Seem to be leaning toward cold.

 

+1 for fly Navy
The Lisle plug removal tool works well
Get one and use it
It works
NEVER be ashamed
We all make mistakes, and you made none
Those plugs simply break off in there
In the future
Replacing them hot does help
Use the tool
It'll pull the broken part up and out no problem, and then you can just replace the spark plug.

 

tcruz0004,

It’s been a few days since you last posted. Have you resolved this issue and if so, please post the solution? Feedback is important so that we all learn solution paths to these issues.

Thanks in advance

Jimboy

 

Thanks for checking. I've got a few other projects going on right now and it runs right now so It'll probably be a few weeks. I will definitely follow up with results though!