Removing a Broken Spark Plug

Here is how I removed a broken spark plug from a 2002 Dodge Caravan 3.3 engine. Along the way the Ez Out extractor broke so I had to remove that as well. So it's a video on both jobs.

[@jetd6764]

U are very cool and calm throughout the whole process without cursing.......lol.

[@Alan_Edwards]

Comes with age I guess. Thanks for the comment.

[@cdee6096]

The amazing thing is not that you got the plug extracted, rather you remained so calm throughout the process.

[@SladesVWBeetle]

C Dee I was thinking the same thing!! Remaining calm is always the best, but that would have really tested my patience

[@stevecocran4899]

Good job

[@Wildavismedia]

The dog started crying when the extractor broke.

[@Alan_Edwards]

LOL....I never noticed that until you mentioned it. That was my old Beagle who did not like being kept in the yard when I worked. Too funny !!

[@lesliegordon7673]

I just had the same thing happen to my 2004 grand caravan. Mine broke off in the back and made things even harder. I used an irwin ex-6 at first and then ex-4 to get the other half of threads out. Yes it broke in 2 pieces what a nightmare. I ran the van on 5 cylinders to get it good and hot before using the extractors but it worked. Great video!

[@Mr26Huffy]

I've been twisting wrenches for 4 decades now and I can't tell you how many times I have seen this issue. When replacing spark plugs always use anti-seize paste on the threads!

[@BlastReadingSeries]

That's resolve, man!!! Thanks for posting this.

[@dannork1240]

Thank you for this video! I have two broken off plugs on my van, on the back side of course👎🏼 Watching this helps to know what I’m up against though

[@Alan_Edwards]

It's not fun either way and much more of a pain on the back side. Good luck mate. AE

[@georgiojansen7758]

use a xzn bit slightly bigger than hole. freeze the bit and the wrench preferably with dry ice, then tap it in, wait to acclimate and remove slowly.without the freezing it took me about 15 minutes. sparkplugs who are tapered tends to get stuck...goedendag from holland

[@markferraro5250]

what size easy out worked on those long 14 mm plugs? thanks

[@joevignolor4u949]

Heating the threaded, broken off part of the plug with the torch was probably counterproductive because you were expanding it tighter into the hole. What might have helped would have been to run the engine on 5 cylinders up to normal operating temperature. During this time the cylinder head would have gotten hot and expanded while the broken plug would have stayed relatively cool because of the cool air blowing back and forth through it. Doing this would have expanded the hole away from the plug making it easier to remove. You would get a check engine light and a P0304 code, but that could be easily cleared after you got the new plug installed.

[@Alan_Edwards]

I come across that a lot when using a torch to heat something up. Am I going to make it easier or harder? It can be a little confusing sometimes, to know exactly what part will expand from the heat. In this case I think you are correct. For some reason it did not cross my mind while I was struggling with the issue. Thanks for the comment Joe. Hopefully it will help someone else out. Too late for me !!

[@joevignolor4u949]

Thanks. One thing I forgot to add. The spark plug wire that normally goes to the broken plug has to be connected to a good plug that is not installed in the engine but is grounded to the engine block. This is so that the opposite plug across the coil pack still fires its cylinder to help heat up the engine. You also don't want the opposite cylinder misfiring and dumping all that unburned air/fuel mixture into the catalytic converter. Also, obviously, the engine will make a lot of noise running with the broken plug - making a phit-phit-phit sound as the compressed air is pumped out through the busted plug.

[@mikegruenes2649]

Heat makes it expand and then contract. It's simple metallurgy.

[@capri8225]

Guy does look like triple h lol good job. I know this video has been around awhile

[@Alan_Edwards]

I've heard the Triple H thing a few times, but I get more Walter White - esp when I have my sun glasses on.. Getting back into some new videos soon. Whole series on a 2010 F150 truck bed replacement and repaint. Should be good. Stay tuned.

[@frankgrant4784]

Who was the manufacturer of the sparkplug? Are some plugs more prone to this type of breaking?

[@Alan_Edwards]

Oh my gosh I can't really remember it was so long ago now. I suspect it was an Autolite, since I believe that is the OEM part for the Caravan but I am not 100. Honestly it has only happened to me maybe twice in my life so I don't have enough data to suggest it's one manufacture over another. Interesting question though.

[@mrgq1969]

you did a lot better than me ida been cussin a blue storm! lol

[@OffGridInvestor]

Kinda wondering if the blowtorch heating wasn't evaporating all your oil away.....

[@Rialas]

Great job.

[@charluszhang9616]

Thanks for the sharing! I have a question while I am struggling in a same situation (and probably harder as the spark does not give me much space to work on it). I have a question about using torch to heat the engine. Did you drain the oil and empty your gas tank? Is there something should be cared about to avoid explosion or other damage to the engine?

[@Alan_Edwards]

Hey Charlus, I don't know if you're still working on this or not, but in my opinion I don't think there is any cause for concern with the oil or gas tank. Heating it does not create any sparks, but even so the heat applied is pretty localized so I would not worry about any chance of fire. Hope that helps and good luck.

[@charluszhang9616]

​@@Alan_Edwards Hey Alan, I finally got the spark out yesterday. As the spark still has a rounded nut can be griped, I heated a smaller 12-point socket to soft and tap it on the nut, apply penetration, then got it out like a charm. Thanks for your inspiring video! BTW, a mechanic suggest me not to heat the engine directly for safety reason, thus I choose to transfer heat through a socket.

[@Alan_Edwards]

@@charluszhang9616 Sounds like a solid solution. There is always another way to get the job done. Or like they used to say in a less PC world - skin the cat. Yeah I did have concerns over heating the engine, but at that point I was sort of out of options. Thanks for the comments. AE

[@Aventuras_en_Moto_Hn]

good vídeo, same trouble i use trupper tools for less than 3 bucks big deal,, 3 minutes ready thumbs up

[@JUANLOPEZ-dl6ux]

I got to give it to you you have patience I would have probably freaked out

[@--JohnDoe]

did you heat it up with the easy out inside?

[@bthompson1767]

This is why you torque bolts and such

[@stargazer-tf8rw]

what should I do if the ez out wont turn into the threads as it should? I cut half an inch of my finger off the other day but am still able to use quite a bit of force but am afraid I'm going to break the extractor and further damage the finger haha....I can't afford to take it in for 25-3500 just to repair and I dont have the equipment to remove the head :/ any suggestions or should I say F-it and junk it? it runs pretty good otherwise. My guess is when I bought it used 3 yrs prior to replacing the plugs I should have given it a check up upon purchase :/ Silly me for not thinking before this fatal leap of fate for my van? grrrrrr lol

[@mikelooker6739]

+samantha zimbelman if your in MN $100 ill extract it!

[@markgreen8752]

awsome,thankx

[@OriginalHawk]

I have the same exact problem. How did you get the ez out all the way in?

[@Alan_Edwards]

Hey Patrick sorry for not replying sooner. I guess by now you've dealt with the problem. But just to answer the question. The EZ-Out uses a reverse thread so as you turn it to the left to loosen it, it actually tightens itself to whatever you are trying to remove. The key here to me is to use the largest EZ-Out you can so it makes contact nearer the thickest part of the tool. I normally tap them in a bit to get them to bite before I start to turn them. Just seems to help them bite quicker. Hope that answers the question and helps a bit. AE

[@viknevsky4301]

Thank you its helpful ..

[@Alan_Edwards]

Glad it helped you out.

[@flygitt]

OMG it's tripple H working on a car jk LOLOL 😂

[@Alan_Edwards]

Don't tell anyone. I am incognito.

[@ruthspeer5390]

odd question is wd40 and liquid wrench anything like ez out? or should i use only ez out? and where can i find it?

[@GCrane21]

Ruth Speer an ez out is the tool he is using to remove the plug, Google ez out set

[@GCrane21]

Ruth Speer an ez out is the tool he is using to remove the plug, Google ez out set

[@leagueofshadows5133]

This is what triple H will look like in 20 years! Twins

[@tomg7008]

remove the easy out with a strip nut remover ,you should go to a tool store and buy a pro quality easy out .

[@AdrianJayeOnline]

mistake one, using ANY kinda snake oil to fix head gasket leaks

[@Alan_Edwards]

I would have to agree. I should have known better, that stuff never worked for me even for a small radiator leak. Lesson learned.

[@johngalv9288]

you would think spark plugs should be built better to avoid this problem...this can be a real headache.

[@thrashingmetal]

it's the user who don't use antifreeze paste before putting them in ugh

[@Nerdiasme]

Nah, making bigger profits with lesser quality materials is the problem !

[@panicroom4068]

what if all else fails?

[@joevignolor4u949]

You would have to pull the head off and try to get the plug out or else get a new head.

[@blackiechong4344]

This is one good reason NOT to let plug go 100,000 miles Change them every two years or 50,000 miles whichever comes first. These noobies think they are good mechanics but in reality they just suck at being a mechanic

[@shawnv1463]

Don't buy auto zone easy outs, buy quality easy outs drill bits and the like... cheap tools for cheap jobs,,,, But good tools once or cheap tools often

[@Alan_Edwards]

I hear ya brother. I just needed something quick at the time. Most of my tools are high quality for sure. My father used to tell me the same thing. Buy a good tool once, buy a cheap tool twice. AE

[@JuniorBuda]

El problema con este señor es que todo lo quiere arreglar con un perico y a martillazos

[@markroderick3300]

btw you are using the adjustable wrong never put the pressure on the movable jaw look it up if you don't believe me

[@Alan_Edwards]

I don't have to look it up...I know better from years of experience. It's much more likely to slip the other way. But you do what you like mate and thanks for the comment.