How To Remove Stuck Spark Plug from Aluminum Head-Step By Step Guide

Is your spark plug in the cylinder fused to the engine?

It’s quite common to face issues with a stuck spark plug when running it for a longer time. Never try to discard the spark plug forcefully. It will shear off threads in the aluminum head instead. Thus, you have to pay a lot for repairing the aluminum head in the cylinder. 

Although it takes more time to remove the stuck spark plug without any damage, it can save your repair bill up to $500-$1209.

Now, will you go for paying an extra bill or trying to remove the plug slowly?

Of course, you will choose the second way. Then let me tell you how to remove stuck spark plug from aluminum head effortlessly and replace a new spark plug.

Let’s have a try:

How to Remove Stuck Spark Plug from Aluminum Head-Step By Step Guide

I will share my experience and knowledge about removing the spark plug here, that might become helpful for you and you can easily do them step by step. 

Look for the Top-Quality Rust Penetrating Oil:

Most of us have a wrong conception about WD-40. We know it as penetrating oil. But actually, that’s not true. WD-40 is a common lubricant that can be used for general purposes.

And I think it works as a marginal rust penetrator. To be honest, when it comes to removing the stuck spark plug using WD-40, it works a little bit. Besides, it often causes unpleasant damages instead.  

If you truly want to remove a stuck spark from the aluminum head, you need to find the best penetrating oil for stuck spark plugs.

However, you have the right solution here. You better purchase one of the highest quality rust penetrating oils than wasting money on a WD-40. 

There are so many penetrating oils available in the market. Among them, the best penetrating oils are PB Blaster, Knock’er Loose, Liquid Wrench, and Freeze-off. Choose one among them and buy from any home center or auto parts shop. 

Start the Process by Soaking up Wastes:

Now, your task is to wash out any dust or debris around the spark plug if it remains. After blowing out wastes, you have to sprinkle a liberal spray all over the spark plug’s base. 

When you complete spraying properly, the only job is to wait for up to 30 minutes. After that, you can have a try turning the spark plug. 

After that Attempt to a Quarter Turn:

Only a 30-minute soaking is not enough to remove a seized spark plug. It’s a weary task undoubtedly. But the first attempt may help you drag the plug a little bit about ⅛ to ¼ turn. That’s enough for the first run.

Then put the socket of the spark plug on the plug and attempt to move it by ¼ turn. If it doesn’t work, try to tighten it by ¼ turn. 

Your main priority should be shifting the strings well. It helps the rust penetrating oil to grizzle into the threads. Then try to turn the plug. Keep adding penetrating oil until it is properly removed.

Go on turning, stop, and then add more penetrating oil and again turn. 

Tighten the Spark Plug:

It is important to let the spark plug seat properly. Thus, continue tightening the spark plug until it places correctly. Use more penetrating oil to do the process easily. 

Loosen the Plug until You Get Proper Resistance:

Getting enough resistance is very important. For this, loosen up the spark plug using more penetrating oil. Do the process until you get the proper outcome. 

Keep going on tighten, loosen, and penetrating oil step until the plug removes…….

Now, you have to clean up the penetrating oil as much as possible. Wash out the threads of the spark plug in the cylinder. For absorbing the oil you can use a dry rag.

Give a final cleanup to remove the remaining traces of oil by spraying the threads and seat. Blow out the oil using compressed dry air.

Establish the New Spark Plug:

After removing the seized spark plug, it’s time to put in a new spark plug. Avoid coating the threads with anti-seizing. If the product’s manual instructs to anti-seize, then go for it. It is important to attain accurate torque.

You better try and use a torque wrench for obtaining the correct torque. 

That’s all about how to remove a seized spark plug when it gets stuck on the aluminum head in the cylinder. Hopefully, the simpler steps will save your repairing cost.

Do follow the techniques and enjoy the auto repair advice. 

Important Frequently Asked Questions (FAQs):

Can I use WD-40 to loosen spark plugs?

In a word, absolutely you can use WD-40 to loosen up the spark plug. This universal product can be used for a variety of purposes. It is a degreasing agent that helps withstand water from spark plugs. It also impedes eroding by keeping the moisture away from the spark plugs. Besides, WD-40 assists in loosening up spark plugs to remove them. 

Should you use anti-seize on spark plugs in aluminum heads?

No, there is no need for anti-seizing spark plugs. Because modern spark plugs come with a stable nickel coating to ensure extra protection of the aluminum heads in the cylinder. The nickel coating also protects the plugs from seizing. Therefore, it is not vital for the anti-seizing of the spark plug. Besides, anti-seizing often results in the risk of breakage of the spark plug by distorting the tightening torque up to 20%. 

How do I remove spark plug threads from the aluminum head? 

Removing spark plug threads from the aluminum head is quite easy. Just follow some quicker steps: 
1. First of all, shift the piston to the bottom dead center in order to remove the spark plug. Before shifting the piston, let the engine cool down. 
2. Then, it’s time to soak up the broken plug shell using high-quality rust penetrating oil. Add generous amounts of penetrating oil if you need more. 
3. After that, leave it for a couple of minutes. Then, install a correct size new spark plug into the empty shell. 

Do you need a magnetic socket for spark plugs? 

If you prefer a more reliable and last longer spark plug, you should need a magnetic socket. Although you’ll rubber sockets at an affordable cost, they won’t give you reasonable performance. But rubber sockets won’t disappoint you as they hold up spark plugs in place. The magnetic socket does the job more precisely. Plus it is more durable than rubber sockets. It also gives you long-term performance. But magnetic sockets are more pricey than you think. As you know money makes value. So, it depends on your preferences to which you will go. 

Can a broken spark plug damage the engine? 

Don’t do that. Never try to drive your car when the inside spark plug is broken. If you drive your car with a piece of broken spark plug it may result in damage to your engine. Often it causes severe destructive engine failure. Then it costs a lot of money to repair the damage. If you have issues with the spark plug, you better remove the broken plug first, reinstall the plug, and then drive the car. 

How can I tell when a spark plug is bad? 

There are probably a lot more signs for telling when the spark plug is poor. Let’s talk about the general signs you can face: 
1. The car won’t start promptly
2. The engine gets misfired often 
3. The car will be a rough idle
4. The engine may burst 
5. The fuel consumption gets elevated than normal 
6. The car won’t accelerate properly 

What tool do I need to remove spark plugs? 

In order to discard the spark plugs from the car, you require a couple of tools. Most importantly, you need a socket wrench along with an extension as well as a spark plug socket.

Spark plug sockets are available in different sizes including 5/8 inches or 13/16 inches. It helps to hold the spark plug in the exact place. There is also one more important tool to use. This is a universal joint.

It assists you in turning the wrench on one axis and also converting the motion into another axis. Plus, sometimes you may need a couple of boot pliers, a rubber tube, a rag, rubbing alcohol, or compressed air. 

Last Few Words:

I have shared my own experience and knowledge on how to remove stuck spark plugs from the aluminum head in the cylinder. Hope my step-by-step instructions will get your problem solved.

Thanks for reading.

About John M

John contributed as a technical head at an automobile company just 2 years after his post-graduation in Automobile Engineering. He loves to lead a free life, so he left his job & started blogging. Now, he does research on every automotive problem, part & product and seeks a better solution & best products & shares his findings with his readers to help them as well as to minimize their struggle.

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