I had replaced the original plugs with Delco AC60s. All were torqued to spec.

The engine's been hard to start, so checking the glow plugs, I found several with the spade terminals broken off, so I ordered a set from Kennedy Diesel.

Today, I tried to change out the plugs, but after loosening the first one, the head would turn, but the plug would not come out. The second was hard to turn, so I quit.

I suspect the shaft has sheared.

Gotta figure out how to remove them without pulling the heads.

I wish I had an easy answer for you Rusty.

Perhaps the glow plug tip mushroomed outward and you're unable to get it out because the hole is smaller than the tip of the plug is now.

Are you capable of tightening it back down?

quote:

Originally posted by Bill N.Y.:

Perhaps the glow plug tip mushroomed outward and you're unable to get it out because the hole is smaller than the tip of the plug is now.

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The element mushroomed on my 6.9 ford diesel. I ended up breaking the glow plug off. So I just started the engine. Now it is jammed up into the hole. She runs ok and does not his or leak. I was told by another diesel mechanic it would eventually shoot out like a bullet. No luck with the compression pushing it out yet. The last time I changed the glow plugs I put never seize on the glow plug threads. I wonder if the never seize caused the glow plug element to swell up bigger than the threaded hole. The other seven glow plugs came out fine.

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Maybe try starting the engine, but put a big layered towel on the glow plug. It could go right thru your engine cover.

5.9B Cummins. I do not have glow plugs, but I did change injectors. Had to put a nut on the top and use a slide hammer to get them out. Harbor Freight sells slide hammers.

The plug is still threaded in the hole. I doubt it's mushroomed, as the plug did not back out at all. It doesn't tighten back up.

The engine should run OK, and I'll take it to my local shop to replace the remaining ones and pull the head if needed.

impact wrench!

Won't do any good when the head is sheared off...

Check youtube- glow plug removal tools.

Thanks - good snag.

My plan is to start the engine tomorrow; if the plugs hold, just leave 'em be for now. If the pressure blows the core out, tap and insert a screw to plug the hole until I can get it worked on. Might try the other plugs with the heads warm.

quote:

If the pressure blows the core out, tap and insert a screw to plug the hole until I can get it worked on. Might try the other plugs with the heads warm.

Would an "easy-out" work?

There are kits (which I found thanks to Tom&Julie) with everything needed to extract broken glow plugs. However, I ran the engine today and the broken plugs core remained intact. Tomorrow I plan to run the engine again and try the remaining plugs with the engine warmed up (had too many other things to do today).