This isn't for a thirdgen, but I'm sure someone has some ideas that can help me. Had today set to do some work on the wife's car, a 99 Cavalier. Changed the air filter and oil, and was going to change the spark plugs as well. The car was still warm, so I left the plugs, and started working on my TA. I have an edelbrock performer rpm manifold in the garage, so I ripped off the stock one and got everything ready for the new manifold. At this point it started to lightly rain, so I decide its more important to get the wifes car done and finished first. I touched the head on the Cavalier and it was cool, so I wasn't too worried about stripping the threads in the head (its aluminium). I change the first three plugs with no problem. Get to the last plug and the damn plug broke off inside the head! The plug threads and the ground strap are still threaded in the head. The plug broke right where the threads meet the nut/socket thing on the spark plug. I was to mad to do any more work on the car today. I have some ez outs which i'm going to try tomorrow. I hope i can get the threads out this way, and not break the ground strap either, wouldn't want it falling into the cylinder. The electrode of the plug came out with the spark plug. I can actually see into the cylinder. If that doesn't work, I'm going to have to get someone else to get them out. I just hope the head doesn't have to come off for it.

Anyone have and tips or advice on getting the threads out?

Thanks

 

Apply liberal amounts of penetrating oil as soon as you can to allow it the maximum amount of time to work into the threads. There are a lot of good products out there that can help. Blaster! formula PB works pretty well.

Try to use a straight fluted extractor instead of the "standard" left-hand twisted E-Z Out type extractor. The thin shell that is left in the hole will tend to expand and bind rather than unscrew with that type extractor.

If/when you do get the plug shell out, install the new plugs with anti seize compound applied to the threads, to prevent this kind of thing from happening again. Aluminum castings with steel fasteners threaded in tend to fuse to the steel, creating the problem you describe.

 

I would recomend doing what was already stated above in fact I would add the penitrant now and a little more awhile before you dicide to remove the threads. also along with using the strait easy out you should turn the plug threads as if tightening a 1/4 turn first. I have found that things like to break loose that way for some reason. good luck!

 

Vader pretty much summed it up, but i'll add this: if the ez outs fail try to add heat, i would use a heat gun not any kind of torch. and my secret weapon, a product called aerokroil, actually its called kroil but the aerosol version is known as aerokroil, hands down the very best penetrating rust buster, if you can find it you will not believe what it can do.

http://www.thomasregister.com/olc/kano/kanopnlu.htm

i just searched this sight, you can see/order it here.

 

I have had this exact thing happen before. I used the easy out and nothing else. I got lucky and the threads really were not in there very tight. It came right out. Then I hooked up the shop vac and sucked whatever could have fallen in there out.

When I was in the military I can remember a few occassions when mechanics would accidently break off glow plugs into the Hummer motors. They would just clean the threads up letting whatever drop in there and fire em up and take off.

 

Thanks for the info guys. The ez outs I have at home at the straight type. I've had bad luck with the screw type extracters before. I'll spray it first thing in the morning, and let it sit for a while before attempting to pull the plug out.

 

laiky is right about the Kroil, That stuff is amazing!

 

Just thought I'd let everyone know i was able to get the plug out with the ez out and a 4ft pipe. It was stuck in there pretty good. I figured i had nothing to loose if i stripped the threads, because if it wouldn't come out, the head would have to come off so I could drill out the plug threads. I'd have to heli-coil it anyway. But, got lucky, no stripped threads and everything checked out ok, new plug went in ok.

Thanks again for the input!

 

With anti-seize compound, I hope. Don't MAKE me come up there and kick you in the shin the next time this happens...