Plug Wire End Broken; Plug #2 Frozen

[spoke]

'86 930

Changing spark plugs and plug on cylinder #2 will not budge. I have a 3/8 in ratchet with swivel and I can feel something stressing as I try to remove the plug. This plug will not loosen. How do I get this plug out?

Next issue: looks like several of the plug wire ends are cracked. No problem, will replace the wires. However, one plug wire end is still on the spark plug. I can't see it or feel it. It's cylinder #1. I'm thinking I can remove the valve cover to get some clearance.

[porschedude996]

It looks just the rubber sleeve/hood/boot barrel shaped thingy. Maybe snag it with a wire coat hanger?

[smadsen]

If you can't break it loose by twisting it, I've had luck using a long screwdriver as a lever and prying straight up.

When you replace the wires, I'd recommend a little dielectric grease up the boot to: a) seal up the boot from moisture, and b) keep the boot from sticking to the plug during removal next time.

Good luck.

[cmcfaul]

Bummer, one of those simple projects that turns into a nightmare. Magnacore plug wires (the big ones) I like best. Broken a few of the stock versions.

Muscle up to get the plug out. Use a breaker-bar if necessary.

Chris

89 Carrera

[JSV798]

You need to be using the correct tool. Here is the tool I use, had it for more than 40 years:





It has a 10mm allen key socket at the knurled end.

Roy

[AlKidd]

Although your probably beyond this point, Ive had success pulling stuck plugs from hot engines. A little of your favourite penetrating oil around the offending spark plug and couple heat cycles may help loosen the seat too.

[gdp_samson]

I had a similar issue some years ago - boot snapped of halfway...i bought a metal tube that snuggly fit over the part that was left behind in the engine, and put super glue in the inner diameter of that metal tube.

Shoved it over the part that was still sitting on the spark plug and let it sit for some hours...then gently straight upward was able to remove the metal tube with the broken part glued to it. Then was able to remove spark plug in the normal way...

posted it on the Belgian Porsche forum, will look up the link...

[gdp_samson]

https://www.porscheforum.be/forum/4-911/128141-eenvoudig-vervangen-bougies-diy-worst-case-scenario

it's in dutch but the last picture shows the final result...hope this helps

[Nditiz1]

cruddy luck spoke. Removing the valve cover will definitely give you the extra space required. Maybe some long needle nose if you can get it in there.

[spoke]

Originally Posted by gdp_samson

I had a similar issue some years ago - boot snapped of halfway...i bought a metal tube that snuggly fit over the part that was left behind in the engine, and put super glue in the inner diameter of that metal tube.

Shoved it over the part that was still sitting on the spark plug and let it sit for some hours...then gently straight upward was able to remove the metal tube with the broken part glued to it. Then was able to remove spark plug in the normal way...

posted it on the Belgian Porsche forum, will look up the link...

This is a great idea. I didn't want to look for a metal tube so I printed a tube to pull out the plug socket. Actually printed a few of them until I got the right size. Even there I had to chop off some of the base to clear the heater tube as this was in #1.

Put superglue on the tube and waited overnight. Came right out. The tube on the right is the one I used. The plug socket is still attached.