The tap method sounds like a good bet.

Another thing I would try is putting a little JB weld on the threads, thread it in gently and let the epoxy set up for 24 hours, then try using the tool.

 

$4800 will almost buy a re-man motor.

 

I hear ya there... Most of there quoted price was to pull and install motor, all labor. Parts were a very small part of the quote. Here in Northern NY its a constant fight with rust and corrosion, so that wouldn't help matters either. I picked up a tap the size i needed, and a regular extractor to see if i can get a hold of it. Will mess around with this afternoon. I can try a lot of things for way less than $4800.

 

I was able to get a good bite on one of the broken plug shells with a traditional extractor, but of course had no way to pull it. Think I'm going to weld on a piece of 3/8 all thread, make up my own puller and give that a try. Won't have access to a welder until I go back to work, but worth giving a shot. I tightened down on it enough that I was afraid the extractor might break, so it has a good bite. Will let it soak in the meantime.

 

Keep us up to date buddy and praying for you..

 

Wish I was coming here to give some good news, but unfortunately not. I was working on the front driver side plug. Made myself my own extractor by welding an extractor onto a piece of all thread. Prior to using this extractor I was able to get a good bite onto the shield by grinding down the shank shoulder towards the bottom of the lisle extractor. Same problem as before, it would tighten down good, but when i tried extracting it just pulled pieces of the shield, not the whole thing intact.

This has been soaking for about a week now, it just must have been in that good so I thought.

I put my home made extractor in and tapped a few times to get it started and thump.

You guessed it, dropped right through. The bottom portion of the plug is no where to be seen, extractor came out empty. Just to be sure I wasn't seeing things I threaded a new plug into the hole and it was fine. But knowing that piece is in there, of course I took it back out.

At this point I think my time with this job is done as I won't be able to get the electrode shield out. The cylinder is towards TDC, but without a camera I can't verify what is actually down there.

On a small bright note, I did get one shop to quote me 20 hours labor at $60 an hour, plus parts. That will be able half, if that of the original $4800 bill from the local Ford Dealer. Downside is the main mechanic is out with surgery until early september. I've been borrowing a truck for 1 day a week to get by for now. My DD is a 2005 dodge stratus with 185k miles and tired and rusty. I got myself in a pinch I guess, but it is what it is.

Thanks for all the suggestions!

 

I would try a Vacuum cleaner with a clear gas line hose taped to it and stick it down there and see if it will suck it out....this is what i did when some of the metal bit's fell down in there.