2006 f150 5.4- Removed 5 that where broke and the pusher/extractor tool worked great, on the 6th one while slowly backing the extractor out it broke off at the threads!!! So now the plug tip and extractor threads (half of them) are stuck in the head.

Open to ALL suggestions. Thanks.

 

wholy crap that's terrible. I can't think of anything other than pulling the head. unless you can, well first of all find out how much of the broken tap you have to grab by. maybe if there's a 1/4" or more, you can machine like a clasp like on your drill chuck to grab it by the outside. Also if you have partially extracted the sleeve, maybe you can grab the outside of the sleeve with a similar tool.

Out of curiosity what brand of tool was that? Do you think you did anything wrong to make it break or was it a bum tool.

 

Man that sucks. Post a pic and maybe one of us can come up with an idea for getting it out.

 

Yes it does suck guys!!! Got a new tool today and all plugs are now out except the one with the extractor broke in it.
I'd rather not say the name of the tool company just yet till i dicuss it with them.

Guys there has got to be a way to get this one plug tip out without pulling the head, that is a MAJOR ordeal and cost.

One thought i have is to try and "push" it all down a little farther so maybe i can get the new extractor in there????? if that worked i'd just have to het all the debris out of the cylinder.

Open to all thoughts, Thanks.

 

Hey Bloodvette, appreciate the ideas. The tip of the extractor is down in the sparkplug tip, so there's nothing to grab on to and it appears its still in place and has not moved, that's as best i can see with the mirror, it's on #3, second from back on passenger side.

I had just pulled 5 plugs out with it, i did this one the exact same way, so i don't see how i did anything wrong to cause it to break, i got a new tool today and pulled the other two, and that #4 in the back is tough!! And VERY nerve racking!! -after that breakage. A flawed tool i guess, i don't no man............just my luck.
But it's GOT to come out!!

 

I would definitly call the company that makes the tool and see if they will pay for the damages

 

inabind, if you pull the computer off the firewall and its bracket, the rear 2 are not a problem at all. OF COURSE, both those plugs broke for me and i had to extract them, but if a guy left the computer in, it would be really hard to get in there. but yea you are reaching deep deep to the back, its definitely more time consuming.

We have a tool at work for pulling bushings that bites on the inside of a bore. Kind of like a gear puller with the teeth pointed outward... maybe something exists that you can get down in there to bite the inside of that sleeve. may have to make one.

Also keep a slide hammer in mind. IF some way you can attach something to that tap by welding rod, or drilling into it, then with your slide hammer you might pull it. Maybe get yourself a really long, good quality, drill bit. Make yourself a centering tool so the drill bit stays centered in the tap, and try drill it. And I'm talking a small bit 1/8" to 1/4" and weld an easy out to a rod. a Thick rod maybe 3/8". becuase you need it to not twist as your tightening that easy out in there. and once you get that easy out good and tight in there, hook it up to your slide hammer and tap tap tap-a-roo.

in hind site, you probably can't drill into that tap, and nor would the easy out want to bite into the tap even if you could get through it. hmmm.... brain teaser.

 

Thank You 70f100longbed!!!!!!!!!!! (From Ford Enthusiast, ford.trucks.com) got a 8 1/2" punch today ( thank you Harbour Freight), sharpened it on the bench grinder. Used the body pusher as a guide so as not to mess the threads or head up, hammered the punch in and eventually broke out the extractor, retrieved the pieces with a magnet and after much PRAYER and forcefull persuation got the new extractor started and pulled the plug tip...WOW!!!! What a nerve racking ordeal!!

Now to get the pieces out of all the cylinders.

Thanks again 70f100longbed and all the other guys input.

 

Lucky is an understatement for this situation, --=phew.
One thing I learnt many years ago, it works every time, (well except for stupidity sometimes, lol). In a situation like these plugs seem to be, never buy a tool not designed & proven for the task, never use a "like" tool, kind of like buying a rice rocket, removing the baffels and saying "it almost sounds like a Harley", if ya wanted a Harley, you buy one!!.
Buy the same one a true mechanic buys. If you still run into a problem, talk to a Nappa guy, snap on guy or Matco tool guy, they talk with & sell tools to real mechanics more than most any other place. They have solutions for solutions, no joke! They can & do get us out of some problems we get into.

Congrats on getting it out!!!

 

It was a Matco tool that broke.....Lisle 65600 that got the rest out (from Snap On)