Anyone got a new tip or trick to remove a stuck spark plug boot? (1 Viewer)

[Kernal]

Haven't run into this a long time. Anyone with special tips/tricks on removing a stuck spark plug boot (FZJ80)? Got the stem out, but can't get the boot off, tried picks to pull it off the spark plug, no go. Next I plan to bust it up (and maybe break the spark plug tower) or maybe melt it with a propane torch??



(Edited for clarity)

 

[Comet]

Picks are the only experience I’ve had to use. Really long pliers will get bits at a time. I hope it’s not cylinder six.

 

[-Spike-]

Blow air into it?

 

[ATXLX]

Don't know if this would help you at this point

 

[clx16]

I had it happen on my taco once. I think I used a scalpel, razor blade (very thin) or something of the sort to cut/shave off the boot along the spark plug. You end up having to vacuum the hole before pulling the plug as you get lots of little rubber bits in there.

 

[Kernal]

Thanks for the tips, will hit it again tomorrow. The frustrating part is that it's a blind operation, can't see anything down the spark plug tube.

I'm leaning toward using the propane torch down the tube to melt the plastic,
I did a test with a piece of the broken stem and after about 30 seconds of heat it was easy to squish the melted plastic. Once it cooled it hardened back up.

So after melting the remaining boot in the tube if I quickly shove the spark plug socket down the tube, wait for everything to cool, then vacuum up any bits and pieces before removing the plug. I figure the melted plastic once cooled will stick to the socket and it'll all come out together??

 

[clx16]

How will you keep your socket on the end of the extension? You will need something to really grip the socket so you can pull it out.

I guess If it gets hard enough to let you loosen the plug or you get down enough to hit the nut portion you might be golden.

 

[-Spike-]

Thanks for the tips, will hit it again tomorrow. The frustrating part is that it's a blind operation, can't see anything down the spark plug tube.

I'm leaning toward using the propane torch down the tube to melt the plastic,
I did a test with a piece of the broken stem and after about 30 seconds of heat it was easy to squish the melted plastic. Once it cooled it hardened back up.

So after melting the remaining boot in the tube if I quickly shove the spark plug socket down the tube, wait for everything to cool, then vacuum up any bits and pieces before removing the plug. I figure the melted plastic once cooled will stick to the socket and it'll all come out together??

You know there's a seal on the valve cover, right? Also, what's to say the plastic sticks to the socket and doesn't stick to the head/valve cover?

 

[Kernal]

clx16: I have a spark plug socket that has a socket extension permanently attached with a swivel joint, so it can't get pulled off. Getting to the spark plug hex is the goal.

Spike: the tube seals are right there, but I plan to change those anyway, being Viton I figured at worst they might get a bit over their normal max temp?? That's a good point about other bits sticking somewhere else, maybe if I vacuum out any little bits first??

There is some oil in the tubes, that should prevent the plastic from sticking to the valve cover around the bottom of the spark plugs (I can spray some silicone down there before I start). The plastic of the boot stem I tested didn't flow when heated, it got squishy with the heat but only when pressed with a screwdriver.

IDK, might try something else, just thinking out loud trying to come up with a way to remove the stuck boot.

 

[CaptClose]

I had this happen. I have a small write up in my build thread. Here is what you need to do....

Builds - Going to meet my new 80

Made a beach run to PINS today. Looks like you got a major award!?

forum.ih8mud.com

It works. Just a few minutes of grinding the boot away and then vacuum up the bits.

 

[OGBeno]

I have a set of hemostats. Work perfectly for this role.

Everyone should have a set.

 

[Kernal]

Beno: what size are those ?hemostats and how did you used them?
Working with some picks I can't seem to get around and below the edges
of the stuck boot. There's just nothing to grab ahold of.

CaptClose: how did you use the hole saw? The post you mentioned
says you attached it to a socket extension, then did you just use a
ratchet to turn it some back and forth, or just push down or??

 

[CaptClose]

Beno: what size are those ?hemostats and how did you used them?
Working with some picks I can't seem to get around and below the edges
of the stuck boot. There's just nothing to grab ahold of.

CaptClose: how did you use the hole saw? The post you mentioned
says you attached it to a socket extension, then did you just use a
ratchet to turn it some back and forth, or just push down or??

I used a hand gimbal ratchet. Can’t remember how I red neck engineered attaching the hole saw to the socket extension, but it wasn’t that difficult with the tools I had laying around. I know it did involve a little duct tape too haha.

 

[8cam]

Don’t use heat. You may end up with a pile of goo in there that will be much harder to get out. Hemostats, a set of extended jaw needle nose pliers, and a good shop vac.

And a beer afterwards for your back. Because it will be killing you.

 

[Kernal]

Already there with the heat and humidity, no shade outside.

The propane torch idea is scrapped.

I got the 7/8" hole saw with a threaded adapter, tried cutting
it a bit but didn't go far as was concerned it might start digging into aluminum.

So I then test fitted a new Denso Iridium plug inside the hole saw and the teeth bottomed out on the steel rim (max diameter) of the plug about the same time the top post of the plug bottomed out on the threaded adaptor, so I shouldn't be able to get past the plug into the head with the hole saw.
Went inside to cool off, hot day.

 

[Kernal]

Update: so went back and using the hole saw attached to a cordless ratchet to drive it went deeper this time and got some plastic crumbs on the saw's teeth so I knew I was into the boot, and no metal shavings so didn't cut into the spark plug. Then using a few different long picks pulled a circle of foam out along with some other bits. Then reversed the shop vac hose to the blow side and using a long narrow funnel with the shop vac hose blew out a lot of small bits of plastic (compressed air with a long narrow nozzle would probably work better, don't have a compressor myself). After that I was able to get a spark plug socket on the plug.

In hindsight, before trying to cut the boot, next time I'll use a long set of curved needle nose pliers and try to grab the remaining boot connector
that was still stuck on the plug; that may have pulled everything up out
of the hole. I really don't know why I didn't do that first.

But if anyone else runs into a stuck boot, here's the tools I used.
A Milwaukee 7/8" hole saw, a 3/8" Milwaukee threaded adapter, then a 11/32" long 1/4" drive socket on the threaded adapter, then a 1/4" to 3/8" adaptor and a 3/8" socket extension. All that driven by a Milwaukee M12 cordless ratchet. The set of 6 long picks was from O'Reilly's.