Spark Plug Stuck: Worn Hex Head.

[JonK]

On Sunday afternoon, I was doing routine Spark Plug replacement, 40k or so on my 05 4.4i N62 engine.

Cylinder 4, need confirmation, close to the driver's side with the least clearance my 5/8" won't grab anything. So I couldn't get it out. Rest of plugs I replaced it with ease. Put them back together now cylinder misfires....

I used the giant dentist mirror and flash light to see what's going on and I was able to to the plug is in there.

I ended up bringing it to a local German Mechanic Store, the older gentleman took a look at it with better flash light with his helper and diagnosed that "THE HEX HEAD HAS WORN OUT and NOTHING OTHER THAN PULLING ENGINE APART CHASE OUT FROM INSIDE WILL HELP.."

It was like a DEATH SENTENCE to my beloved(!?) X5. I have done some extensive web search but not much I could try. Smaller sockets, Kroil Pernetrating oil, perhaps break the head and use screw extracting tool?

On my previous E46 I was able to pull out plug when the top broke off but this time I have a worse clearance, and the top is still intact.

Any suggestions?

[jbfrancis3]

First, I would try to verify that diagnosis yourself (or take it somewhere else to have verified). It would take a lot of abuse to round off the body of a plug and it's my guess that damaging the the threads in the aluminum head would occur first.

Second, if this were truly the case, you can purchase (or locate a shop that has) what's called a bolt extractor. They are essentially a socket, and you want be sure to request a deep socket. Example of a kit: Sears: Online department store featuring appliances, tools, fitness equipment and more

[JonK]

Thanks for the quick reply.
The local mechanic who looked at it said, he has never seen anything like it. I wanted to use borescope (endoscope) to confirm, but he didn't use one.
I agree with your logic thread should go bad first... WD 40 didn't help I had nothing to grab onto, and also never used a power tool to strip anything.

I am running to Sears for bolt extraction tool. Will keep you posted.

[Bulk]

+1 above

[SlickGT1]

You need a set of deep, 12 point sockets. You need to find one that is slightly smaller than the hex. Then take a hammer and hammer it onto the plug. You should be able to remove this without taking the engine apart. I can't see you needing to take the motor apart because of something like this. Go find a Russian mechanic. #1 problem solvers in my book.

[TEMA]

Originally Posted by SlickGT1

You need a set of deep, 12 point sockets. You need to find one that is slightly smaller than the hex. Then take a hammer and hammer it onto the plug. You should be able to remove this without taking the engine apart. I can't see you needing to take the motor apart because of something like this. Go find a Russian mechanic. #1 problem solvers in my book.

we are nice people, you know!?

[SlickGT1]

I do know. Kak dela.

[JonK]

Originally Posted by SlickGT1

You need a set of deep, 12 point sockets. You need to find one that is slightly smaller than the hex. Then take a hammer and hammer it onto the plug. You should be able to remove this without taking the engine apart. I can't see you needing to take the motor apart because of something like this. Go find a Russian mechanic. #1 problem solvers in my book.

That was my second option to try out slightly smaller 12pt deep sockets, 15 mm, 14 mm. (Since 5/8 being 15.7 mm) Irwin BoltGrip is on my way from amazon.com I am gonna try that first.

I don't know any Russian Mechanics in my area. It was a older GERMAN MECHANIC who made that suggestion to take the motor apart. N62 Engine has a plastic nipple (rubber tube extension which is not connected to anywhere in front of the radiator) that I believe it is for vent. He also suggested some part is missing because of that. I don't believe him much despite of his national origin.

Thanks for the suggestion.

[dcardenas]

Originally Posted by SlickGT1

You need a set of deep, 12 point sockets. You need to find one that is slightly smaller than the hex. Then take a hammer and hammer it onto the plug. You should be able to remove this without taking the engine apart. I can't see you needing to take the motor apart because of something like this. Go find a Russian mechanic. #1 problem solvers in my book.

I like this idea!

[JonK]

Just ordered a Cheap Borescope from eBay. ($44) Will upload pictures as soon I get hands on. Thanks again.