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Old 03-05-2008, 07:34 PM
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Top of spark plug broke off!!

I have a 1973 American Motors Javelin 232 six cylinder. Cast iron head and block. I was changing the spark plugs and when I got to number 7 the top of the spark plug sheered off, when I tried to take it out, leaving only the threads and about 3/8 of an inch of the base sticking up still threaded in the head. Looking at it from the top whats left of the spark plug is cup shaped. I have been working on cars for years and have never had that happen before. Very frustrating. Plugs were installed with a torque wrench to factory specs, so it was not over tightened to begin with.

What is the best method or tool for removing this broken spark plug. thanks

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Old 03-05-2008, 07:54 PM
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If all the porcelain is gone, a good easyout will usually get them out. I have removed several like this that were rotted from age. You need to tap it in an a good snap will usually crack it free. I use a socket that fits the easyout and a breaker bar. You want to avoid slippage as it will send shavings into the cylinder.
Chet

Last edited by T-bucket23; 03-06-2008 at 06:03 AM.
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Old 03-05-2008, 08:26 PM
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Easy out technique

Thanks for the info, do I need to drill a hole in the spark plug before I insert the easy out, or do I tap the easy out down into the spark plug like it is? I can see a little round circle where the electrode goes thru so it might go in there.
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Old 03-06-2008, 05:16 AM
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Caution!!!

Can you show a picture of what's left of the plug? is that small hole you describe only about 1/8" in diameter? The reason I ask is that the hole you describe sounds like there is still some ceramic left stuck in the part of the plug that's still in the block.
If so, try to carefully pull the piece back out of the plug using a small tap, screw, or piece of wire. Do not push that piece thru into the cylinder. It will be a PITA to get it back out and will cause damage, either by smacking into a valve and/or getting crunched down to a highly abrasive powder and scoring your cylinder.
Keep us posted,
TR
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Old 03-06-2008, 05:29 AM
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Caution, Pt. 2

Oops, forgot the rest of the procedure. After you get the ceramic part out of the plug, don't drill the plug if you can help it, get the closest size EZ-Out you can find and try to get the rest of the plug out without getting too much schmutz down the hole. A little oil and a little heating and cooling will help.
I hope this helps,
TR
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Old 03-06-2008, 06:18 AM
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Quote:
I have a 1973 American Motors Javelin 232 six cylinder. and when I got to number 7
#7,..??..?? on a 6 cylinder,..??
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Old 03-06-2008, 06:21 AM
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Top of spark plug broke off!!

been in your shoes before
if it broke the part you put the socket on , your in trouble
you want catch the tip or pull out the electrode that in the cylinder side .
get a torch and heat whats left cherry red .
ok , then spray with rust eater or good bolt loosening stuff .
spray allot to cool it quickly .
this will cause it to expand & contract and the penetrate will get in there better .
use a big e-z out 3/8 and drive it in tight .
let it cool completely then .
then use a square pipe plug socket , sears has them .
spray some more juice and keep downward pressure and keep it straight .
i know it's a tight location and hard to get to being back cylinder .
after it's out , you will need to use one them pocket magnets on a antenna
pole you see at counters at parts places .
fish out the tip of plug and electrode .
then use a small vacuum hose taped to a shop vac hose to suck out ceramic guts left .
you then should turn motor by hand to see if no stoppage occurs .
using torque wrench on plugs , never done that in my life or seen anybody do it .
i use anti-seize and hand tighten mine .

good luck with it and try not to cuss it much , a vehicle
is like a woman , you cuss em and get no where .
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Old 03-06-2008, 09:13 PM
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I Got The Spark Plug Out!

OK, I worried over this for two days trying to decide what to do. I finally decided to clean out the ceramic part that was left in the top of the plug. This left a cup shaped area. Blew that out with compressed air. I went thru my nut drivers until I found one that fit perfectly down in the plug. I took the guard off the end of my MIG welder (so I could get in that tight spot) and spot welded the nut driver to the top of the plug. It was a tight fit and a delicate operation. I put a socket on an extension and backed the old spark plug right out of there with a 3/8 ratchet. It worked like a charm. This is my first attempt at this so I was nervous about doing it, but it seamed like the best option. Finished the tune up and the car runs like new. I had a senior moment with plug number 7 in a six cylinder. It was the next to the last plug number 5.
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