Glow Plug Removal Problem *Strange*

Rocky05 · **Joined:** Fri May 17, 2013 11:38 pm **Posts:** 44

So I replaced my glow plugs yesterday, well 3 of the 4.... Plugs 1,3&4 came out super easy, no problem at all. Number 2 is the interesting part. Engine was warm, I used PB Blaster and there was a fair amount or resistance coming out. Well almost out. I can see what appears to be all of the threads and spin the plug easily with my fingers, but it just won't come out!? After messing with it for a few hours and not getting anywhere I decided to button everything back up and see if starting the motor would blow it out. That didn't work, but I can hear a little air getting past the threads while running, and with the wire attached my CEL goes away. Any ideas??? I'm stumped.

dirtmover · **Posted:** Thu Jan 29, 2015 1:44 pm

The hex part at the top can break away from the body allowing it to spin freely. Are you sure you can see all the threads? Can you see the threads turn when you rotate the plug?

The tip can also split, swell or become gummed you with carbon deposits preventing it from being pulled out the hole easily.

Are they metal or ceramic?

Rocky05 · **Joined:** Fri May 17, 2013 11:38 pm **Posts:** 44

Origional ceramic plug, I can see the threads rotating all the way to the head.

dirtmover · **Posted:** Thu Jan 29, 2015 2:23 pm

So, it's got to be split or deformed at the end. Get that piston to TDC and start to soak the plug in penetrant. Let it sit for a bit the carefully try to work it out. Hopefully you've got some carbon fouling as well that you can work out of the way once the penetrant starts to break it up.

BTW, the piston is at TDC so you've got a better chance of retrieving anything that accidentally breaks off.

nursecosmo · **Posted:** Thu Jan 29, 2015 10:20 pm

Try this: https://www.youtube.com/watch?v=fPQLgPk5Mdg

minisub · **Posted:** Fri Jan 30, 2015 7:50 pm

My tough one was #4, the one that had failed. In a nonop condition, the tips carbon up pretty quickly.

I used a chunk of angle that I cut a strip of that was bent out at a right angle. I left the main part of the angle long enough to reach the head and create a fulcrum. In the bent out leg, drilled a hole the same size as the plug body and then cut the leg off through the hole creating a c-shaped "cradle.". This fit just under the hex head and allowed me to turn the plug while applying gentle outward force on the rotating plug. The was just enough to "saw" off the carbon and pop it out. Making the "tool" and getting the plug out took 20 minutes.

Unfortunately, I spent 5 hours messing with it before getting to that solution. :furious:

dirtmover · **Posted:** Sat Jan 31, 2015 11:04 am

minisub wrote:

My tough one was #4, the one that had failed. In a nonop condition, the tips carbon up pretty quickly.

I used a chunk of angle that I cut a strip of that was bent out at a right angle. I left the main part of the angle long enough to reach the head and create a fulcrum. In the bent out leg, drilled a hole the same size as the plug body and then cut the leg off through the hole creating a c-shaped "cradle.". This fit just under the hex head and allowed me to turn the plug while applying gentle outward force on the rotating plug. The was just enough to "saw" off the carbon and pop it out. Making the "tool" and getting the plug out took 20 minutes.

Unfortunately, I spent 5 hours messing with it before getting to that solution. :furious:

Needless to say be very careful and take your time with any forceful extraction. May also want to try something like Mercruiser Powertune or Yamaha Ring Free (yeah boats are another of my vices). Both are pretty good at breaking up carbon deposits. Just remember that anything you put in there to help release the plug has to come out before you try starting it up.

RockyMountainYote · **Joined:** Sun Oct 20, 2013 8:32 pm **Posts:** 77

I had one break in the head. I bought an extractor kit from ebay and successfully removed the stuck part of it without removing the head

ATXKJ · **Posted:** Tue Feb 03, 2015 9:58 pm

RockyMountainYote wrote:

I had one break in the head. I bought an extractor kit from ebay and successfully removed the stuck part of it without removing the head

ebay sells a lot of extractor kits

- do you have a name? number in case someone else want to try it?

minisub · **Posted:** Tue Feb 03, 2015 10:16 pm

dirtmover wrote:

Needless to say be very careful and take your time with any forceful extraction. May also want to try something like Mercruiser Powertune or Yamaha Ring Free (yeah boats are another of my vices). Both are pretty good at breaking up carbon deposits. Just remember that anything you put in there to help release the plug has to come out before you try starting it up.

Yea, very little force was involved.

Old trick from the 6.5s was to use a small piece of aluminum bent into a "U" and vice gripped to the threads. This allowed the threads to keep biting on something and slowly screw the tip through the hole. I couldn't get that to work on #4, so this was my variation on that technique. All that is left behind is dust and a couple cranks with the holes open should be enough to clear that.

Frankly, I was almost at the point of yanking the head just to get the plug out, so little to lose with breaking it.

RockyMountainYote · **Joined:** Sun Oct 20, 2013 8:32 pm **Posts:** 77

This is the same kit I used:

http://www.ebay.com/itm/Glow-Plug-Remov ... ls&vxp=mtr

I should note that the kit came with 2 M10 extractor bolts for larger diameter glow plugs when it should have came with 1 M10 and 1 M8 (what is needed for our glow plugs). That is easily remedied with a trip to the hardware store.

Here are some pictures of the tool's success:

RockyMountainYote · **Joined:** Sun Oct 20, 2013 8:32 pm **Posts:** 77

Watch some Youtube videos and study the tool carefully so you don't drill past the threaded area in the head. Also, when you have the puller itself installed, you'll notice its a little larger then it needs to be and it hits the head casting. You will have to put a couple of washers in front of it, otherwise the tool will start to cock sideways. You want the tool to remain straight inline with the glowplug or you'll end up causing more damage.

https://www.youtube.com/watch?v=ee6sfgIhfT4

Rocky05 · **Joined:** Fri May 17, 2013 11:38 pm **Posts:** 44

Thank you everyone for your responses. I took the CRD to a local diesel specialist, and it scared the crap out of him :ROTFL:

He was actually very smart, and had some good tips, but didn't want to screw me over. Had a couple of his crew try to take it out. Still no joy. Didn't charge me either.

I took it home. Plugged in the block heater. Pulled the injector and rotated the engine to TDC. Sprayed in a generous amount of Mopar combustion chamber cleaner and let it sit overnight...

Bumped it a few times with the injector still out to blow any residuals out (foam and carbon came out). Buttoned everything back up and she fired right up.

At this point, I think I either pull the head, or keep running it like it is. It runs fine.

As a side note; I've been running the GDE tune for about 18 months and put on the Weeks kit while changing the other plugs. The intake was surprisingly clean! (Not like when I cleaned the MAP sensor when I bought it and immediately blew the CAC to intake hose...)

Glow Plug Removal Problem Strange

Who is online