Spark Plug Washer

[Hairy Moose Knuckles]

I tried to use the Thread Chaser in the spark plug hole today, but a few turns and that's as far as it would go. My nephew looked at it and says something is stuck in the threads. He says it looks like a spark plug washer. He worked and worked trying to get it out, but couldn't. He says the threads don't look bad at least all the way to the washer. I have no clue how to get it out.


Any ideas?


On a positive note, he ran the chaser down the other 3 and now the plugs go in with your fingers.

[staninlowerAL]

You could try a 3 corner "handsaw" file and try to gap the washer enough to weaken it, then use a small bolt through the washer hole to put some upward force to try to collapse it. Just thinking aloud.

[Hairy Moose Knuckles]

I tried to use the Thread Chaser in the spark plug hole today, but a few turns and that's as far as it would go. My nephew looked at it and says something is stuck in the threads. He says it looks like a spark plug washer. He worked and worked trying to get it out, but couldn't. He says the threads don't look bad at least all the way to the washer. I have no clue how to get it out.


Any ideas?


On a positive note, he ran the chaser down the other 3 and now the plugs go in with your fingers.

Worked and worked no luck. What ever it is, is stuck solid.

[Don McCombs]

How about trying to post a photo of what is stuck in the hole?

[Hairy Moose Knuckles]

How about trying to post a photo of what is stuck in the hole?

I'll try, Don.

[Hairy Moose Knuckles]

Here you go Don. I know it's not great, but nephew said it's best he can do. I got him to try an enlarge it for you.

[Peter Person]

What did the plug that came out look like?

[Hairy Moose Knuckles]

What did the plug that came out look like?

[Peter Person]

Looks like you either had water get in from the intake or a coolant leak into that cylinder.
Could explain why the engine is stuck.

[Hairy Moose Knuckles]

Thanks Peter. I poured a mixture of ATF and Diesel in all the cylinders.

Just a FYI. I did have a weeping head gasket back when it ran.

If it is one of those two things, what next?

[outdoors4evr]

Those threads look thrashed. If you can't get it tapped clean, then it may be a drill out and helicoil. Before spending $$ on this, I would definitely pull the head, clean it up, and have it checked for leaks and cracks. Find the source of the leak.
Note: Might be easier to tap from the bottom side of the head.

[Dale Finch]

It's difficult to tell, but in the 2nd photo of the plug hole, it does look like a plug washer caught on the threads. IF that is, indeed, a photo of the plug that came out of THAT hole (it still has its washer), the washer could have been left from a previous plug removal. Those washers sort of screw onto the plug bases (they don't easily just slide off), and could have been rusted to the edges of the hole, and when the previous plug was removed, it might have unscrewed out of the washer too.

Of course, if it is a washer, now you need to get it out! You might be able to "unscrew" it, if you can get it loosened...penetrating oil and some light mechanical persuasion. Then poke something like a triangular file down hard, and use it as a 3-sided "screwdiver". Just a thought...

Someone smarter than I will probably come along wih some better ideas!

[Hairy Moose Knuckles]

Thanks Dale. The washer was my first thought as well. I have the cylinders full of ATF/Diesel, so maybe it will loosen a little.

[Don McCombs]

I'm not sure how a sparkplug washer, that has an OD larger than that hole, could have gotten down in the hole. Not saying it absolutely can't happen, but it seems highly unlikely to me. I think it's more likely to be the last few threads of a previous plug.

[Jim Becker]

I'm not sure how a sparkplug washer, that has an OD larger than that hole, could have gotten down in the hole. Not saying it absolutely can't happen, but it seems highly unlikely to me. I think it's more likely to be the last few threads of a previous plug.

Or maybe deposits allowed by a spark plug that was too short or not completely turned into the hole.