I've got a 2001 F150 Lariat - 5.4L Triton - 4WD with a spark plug problem on cylinder #2. I was trying to remove the plug and had a hard time getting the plug socket on it. Tried different sockets, removing the rubbers, etc. There was resistance on the socket that made it feel like it may be loosening the plug, but it never was. When looking in the hole, I could see a good 75% of the plug "nut", and the bottom of the hole. It was clean all the way, and the nut wasn't damaged or rounded. Eventually, I got the socket stuck. Hard!. To the point I had to put epoxy on the end of an extension, push it on the socket, and let it sit overnight. Luckily that worked to get the socket out. Finally, I climbed in, moved the fuel rail, and with a bright light and mirror I could see the problem. (It was in the small part I couldn't see before). There is a small, flat, thin piece of "something" that is wedged between the tube and one of the points of the plug's nut, and it's maybe 3/16" to 1/4" wide. It looks like it would if you shoved a screwdriver down there and broke the tip off. (It's not!) Or, maybe the latch you push to remove the COP connector broke off and fell in. I did replace that connector when I had some broken a while back, but I don't remember the piece falling clear out. I can't tell if it's plastic, metal, or what. I've tried every pick, hook, tweezer, hemostat, magnet, compressed air, etc. to remove it, but no luck. So far, the plug isn't broken. The only thing I can think of doing is cutting a slot in the bottom of a plug socket so it would miss the 1 point on the nut where the object is caught, and try that. Hopefully it would catch the rest of the nut in the socket. Does anybody see a problem I may be missing with doing it that way? Or better yet, have a better idea to get the plug to spin out? I can get the COP boot on it and run it, but it's a rough ride at times. I'm having a problem lately with a bunch of P0301's, a few P0302's, and a couple of P0172's with flashing CEL's. I've been moving COPs and injectors around to see if the problem follows (it didn't), along with checking vac lines for leaks, and all the other good stuff. Any input would be welcomed! Thanks.

 

Super glue on the end of a rod? Wood or metal. Does it wiggle at all or is it jammed tight?

A metal rod heated super hot might penetrate if it's plastic. Are you getting the tip of the compressed air nozzle down beside the plug flats? Might need to build an extension to get the air under the piece.

If you can get a thin piece of metal or wood beside the piece you could put a dab of epoxy on it and slide it down beside. Careful not to glue the stick in to the hole. Let it set and pull the piece out. A variation on the socket trick.

The modified socket seems like it would work but the piece might fall in to the cylinder when you pull the plug out.

 

I prefer removing the object because it could cause catastrophic damage in the combustion chamber. That said, if it's plastic, removing the rubber and heating the socket would melt the plastic out of the way. This ruins the heat treating on the socket and the finish so don't use snap-on.

From doing this tons of times over the years, if the object is wedged in there really well, a long, thin flat blade screwdriver seems to allow one to put more force on stuck objects that other metal shapes because you can twist it. Also you can make tools with burly hooks out of flat blade screwdrivers by cutting a notch in them. This process works better when you use a borescope to observe what's happening in there. My "endoscope" or "borescope" cost $30 on Amazon and uses my phone screen via wifi.

 

You could possibly cut notches in a copper pipe, as in serated teeth and try scraping it out. Or maybe a shop compressor with a high PSI and blow it out
Good luck. These plugs suck

 

Beat me to it ^^^ .

Notch out a piece of 3/4" copper to fit around the obstruction. Might help knock it loose.

 

If the piece ends up falling into the cylinder you could tape some tubing to a vacuum cleaner hose to stick down the plug hole.
Put a piece of filter over the vacuum cleaner hose end to catch the piece.

 

Success!! I finally got the damn piece out of the hole! It was plastic, and it does look like it was the "latch" off of a COP connector. I had a few break in the past and wired in new connectors. Apparently one broke clear off and had been floating around somewhere. I was able to pull it loose with a hook I made from the pieces from a worn out windshield wiper blade. They usually have two long, thin, steel pieces that run along the length of the rubber. One end usually has a notch in it that worked as a hook to get under the piece I was fishing out. If you keep a few around from your old blades, you'll find plenty of uses for them. (They make really good lock picking tools). I was able to pop it up, then vacuum it out with the Shop-Vac to keep it out of the cylinder. Plug socket went on like it should.
Thanks for the ideas here though. BareBonesXL mentioned a "thin piece of metal" and that got me to think about the wiper parts. If it didn't work, I was going for the copper pipe next!
Thx again!