I was pulling my COP off today and apparently the last time I put it on I cross threaded it. The insert that goes into the manifold just spins now and the bolt will not loosen. I tried wiggling and pulling the COP off and ended up breaking it where it bolts on.
I was planning on new COP, so that is not a biggie, but now I have the bolt sitting in the manifold and it will not come out. Tried getting pliers on it and pulling it off, but no luck. I tried making it spin even more to loosen it up more using a drill. It got real hot and spins easily, but still will not pull out and the bolt is still stuck in there.
Anyone had this happen or know how to get this out so I can secure the COP on reinstall?
It is the # 5 COP, so pretty easy to get to.
I am thinking maybe some needle nose vicegrips then trying to loosen the bolt, but not sure if that would work or not since the brass is soft and may deform and end up clamping the bolt inside more.

edit: got it fixed, read below

 

vice grips worth a try, had a similar thing happen on my 4.6 with the #7 coil, spent 3 hrs tryin to loosin it wouldnt budge and ended up threadin the top of the bolt from usin torque wrenches and sockets so had to break the coil in about the same spot then went in and took the bolt out and just put a new bolt the same size as the old one in, think we used vice grips to get it out was about the only option that would work by then

 

Upward force, cut and drill out, or jb Weld are your best options,

 

Well I got it out. Went out there with the drill and ran it for about 30 seconds, wiggling it side to side as I did it and the got some pliers on it and pulled the whole thing out.

Now how to keep my next COP in place? The inserts threads are pretty screwed up at the bottom of it, I might be able to clean the threads up since it is brass. I need a new bolt (2 actually, I tried using one of the other ones to clean up the insert, but it just ended up messing up that one also).

 

Bigger bolt should do the trick.

 

Alot of Lightning and HD guys don't even run screws them them. In fact Weapon X coils don't even have a place to secure them.

Wayne

 

So just drill out the fitting and tap a larger bolt thread?


I was wondering how necessary it really is.

I was also thinking about just using a zip tie to hold it in place. It would still be tight enought to hold it in place, and a fast easy fix.

 

Cross thread a bigger bolt in there. No worries.

 

I would remove the brass insert and JB weld another back in.

 

But where to get a new one is the problem. I searched online and can't find them (don't even know what Ford would call them).

I am leaning toward using my current one and just thread it for a little larger bolt and epoxy it in place.