Cracked off glow-plug recovery

[TOBASH]

Before I tackle my broken plugs with easy-outs and a swear-jar in my 2007 M1165 with 200 amp fuel voltage alternator, I’d like to hear what has worked for others.

Heat

What brand easy outs?

Welding a nut to the broken plugs?

What works best for plugs 7&8 vs other less difficult areas vs from under alternator.

Looking to learn from tips and tricks different from what I’ve done before. There’s gotta be someone doing this easier than me.

 

[wjeeper]

Never broken one in a HMMWV, but have broken a few in equipment. Welding a nut has saved me about 90% of the time. Welding the nut on there really good untill the nut is glowing cherry red, then letting it cool seems to do the trick for me. Accessibility always seems to be problematic in a HMMWV though.........

 

[FlameRed]

I have the same issue. The cylinders they are in are still sealed up holding compression. The experts here correctly advised me to leave them be. The rig starts, but smokes for a few seconds. I can live with it.

I took it all around to the professionals, since I cannot weld, and forget about getting to ones on the pass side.

All except one shop, they all flat out refused to work on it.

The one that was willing to work on it would work on it for $150/hour open-ended by removing the heads and taking it to a machine shop. I think I could swap the engine for less!

 

[TOBASH]

I have been planning on performing the welding technique. I have one additional step. I take aluminum sheet and cut a hole in it so that I don’t accidentally weld to the cast-iron block.

I was hoping there were other methods however it looks like there’s no Royal road to recovery on this

Thank you, one and all!

Special thanks to WJeeper.

 

[TOBASH]

I have the same issue. The cylinders they are in are still sealed up holding compression. The experts here correctly advised me to leave them be. The rig starts, but smokes for a few seconds. I can live with it.

I took it all around to the professionals, since I cannot weld, and forget about getting to ones on the pass side.

All except one shop, they all flat out refused to work on it.

The one that was willing to work on it would work on it for $150/hour open-ended by removing the heads and taking it to a machine shop. I think I could swap the engine for less!

I have several cylinders with bad plugs so can’t just ignore. Gotta take action. Either swap plugs or place Webasto.

 

[wjeeper]

I take aluminum sheet and cut a hole in it so that I don’t accidentally weld to the cast-iron block.

Thats a great idea I never thought of that I will have to start doing! I have a chinesium copper sealing washer set that would work perfect for that.

 

[G744]

"Welding" to cast iron is a difficult procedure. It will be unlikely to get any sort of bond to the head with electric arc.

G744

 

[LCA078]

Can you post a pic of what the broken GP looks like? Knock on wood, I'm not familiar with how these break off...

 

[G744]

More like they twist off when trying to unscrew them.

G744

 

[LCA078]

like the flats get rounded off?

 

[TOBASH]

like the flats get rounded off?

As you are removing them, they crack off at the level of the block.

 

[LCA078]

That reeeeeeeeeeeally sucks.

Best of luck.

 

[GopherHill]

Stay away from cheap easy outs. Easy to break them off and then you have real trouble. Try Kroil soaking for a long time. Be patient! I only use Rigid extractors myself. Do not try knock off sets. The best of luck to you.

 

[sbgarage]

 

[sbgarage]

I've (been so blessed to have) never used said tool above. Leroy diesel used to sell them but since sold out, these are a screenshot from eBay.

 

[Dieselmeister]

I've (been so blessed to have) never used said tool above. Leroy diesel used to sell them but since sold out, these are a screenshot from eBay.

That tool is for removing swollen plugs, after you successfully unscrew them.
It won't help if there is no plug part left outside the block.

 

[sbgarage]

That tool is for removing swollen plugs, after you successfully unscrew them.
It won't help if there is no plug part left outside the block.

Thank you, I thought I was missing something there lol