Overtightened glow plug

fastring · **Posted:** Tue Oct 18, 2011 6:09 pm

Looks like I overtightened a glow plug (#1, nearest radiator). I was very deliberate, even drove to napa to get the right tool, set the torque wrench to 110...but didnt notice it was INCH pounds, not FOOT pounds (seems oh so very obvious now).

Guidance?

Squeeto · **Posted:** Tue Oct 18, 2011 6:18 pm

Steal threaded insert.
You may not need to remove the head. There seems to be cavity that you could fill with cloth to catch the aluminum pieces while you tap.

Better than new.

Others have stated to grease the tap flutes to grab the chips.

audiboy86 · **Posted:** Tue Oct 18, 2011 6:21 pm

What is it supposed to be tightened to and do you mean the torque wrench is ftlbs and you needed inlbs? And if you overtightened it just easy it back all the way out check the threads on both ends if they are both fine re-install it properly

fastring · **Posted:** Tue Oct 18, 2011 6:29 pm

Its supposed to be tightened to 110 INCH pounds. My torque wrench is FOOT pounds, which taking a step back, seems VERY obvious (110 foot pounds is ALOT, why that didnt occur to me a few minutes ago, I dont know).

The glow plug just turns. I guess I need to remove stuff so that I can grab the end of the plug while turning it? With a long deep socket, I turn it to loosen and it doesnt back out, it just turns.

Any suggestions for getting this out?

Squeeto · **Posted:** Tue Oct 18, 2011 7:02 pm

fastring wrote:

I turn it to loosen and it doesnt back out, it just turns.
Any suggestions for getting this out?

Hose pliers may do it.

If you are really desperate/brave, start the truck and blow it out. :!:

Make sure that there is sufficient blanket to catch the glow plug (aka bullet).

fastring · **Posted:** Tue Oct 18, 2011 8:06 pm

I'm not that desperate:) It appears as if it went too far, so if I could somehow apply pressure backing it out while turning it, it would unscrew out. I'm figuring that I'm at a loss at this point and will take it to a diesel mechanic. I'll update the board with how it turned out.

dirtmover · **Posted:** Wed Oct 19, 2011 8:22 am

One of two things has happened:

- You have sheared the plug. This is quite common when removing them and there are threads on how to remove them and specialised tools that your diesel mechanic should have to make this easier. From your description it sounds like it's still in one piece so this scenario is unlikely.
- You have stripped the threads in the head. You will need to have the plug removed and a helicoil inserted. I'm not sure if this can be done without removing the head so brace yourself for a potentially expensive repair

.

Good luck!

fastring · **Posted:** Sat Oct 22, 2011 12:27 am

UPDATE:
- Not much, but they just started working on it and their plan is to remove the plug, if they are successful, they helicoil like the other poster said. Sounds like drilling, then tapping this threaded thing in and then screwing in the plug.
- They compared it to the same process, which they claim to have done many times, on Ford gas motors that spit out spark plugs.
- If the above happens, the head stays on. If they cant get the plug out, then the head comes off...

painemann · **Joined:** Sat Dec 20, 2008 7:02 pm **Posts:** 607

I feel your pain, One of my plugs came out with aluminum chunks stuck to the threads, I was not happy. This isnt as bad as your senarieo but it's not fun when you think you might have to pull the head!
Good luck!

fastring · **Posted:** Mon Nov 21, 2011 5:55 pm

Update: Its been in the shop for the past few weeks awaiting parts. It just finished up today, $3571.47. Ouch. I had the shop do the 100k service while it was in there:
- $1395 labor
- $139 machine shop (once head was removed, needed machine shop to remove the plug)
- Rest was parts:
- timing belt
- timing belt tensioner
- head gasket (two kits, was real suprised how much just the head gasket was, like $400?)
- water pump
- thermostat (I know mine wasnt working)
- some radiator hose
- oil change
- some A/C something, I havent picked it up, but from over the phone some A/C part/work
- Another new glowplug and relay kit, so now I have 3 new extra plugs and an extra relay)

By far, the most I have ever spent fixing a car. I do 90% of my own work (didnt help in this situation...), other than a $2500 transmission on the RV, I cant think of anything $2k or over. I guess I'm committed on this car, but I know a big portion of that is going to be required every 100k miles ($2k worth, roughly if you do a full timing belt change with WP, tensioner, thermostat, etc).

While the Jeep was in the shop, my wife bought a new Prius v (the wagon). She wanted a TDI Jetta Wagon and I must admit that the VW timing belt was the deal killer. My old prius ran 100k no issues with no required big maintenance bill at 100k miles.

racertracer · **Posted:** Tue Nov 22, 2011 3:53 am

2 head gasket kits? That doesn't sound right, I bet you were charged an extra kit becasue they ordered the wrong one the first time around, each kit is about $150.00.

Overtightened glow plug

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