1999 E300TD.

Well, I had to replace a bunch of fuel lines and the shutoff valve, so I figured why not go ahead and do the glow plugs why I'm there. Huge mistake it turns out. Those things were stuck tight as could be. Put penetrating oil all over them several times over the course of the day and tried to loosen them at the end of the day. I read all of the posts on the GP job and figured I did everything right.

One sort of squeaked at me so I put more oil and went to the next. It seemed like it was loosening, but after a while it was obvious that it had spun out. Looks like the head of it with the hex part just sheared clean around. The threads are still nice and tight. Since it broke that way, no way to drill.

I put all of the glow plug wires back on and the glow plug light on the dash acts normally.

It seems like the way it broke the integral parts are still intact and functional. I can't image that if the thing spins that easy up top that the pressure would make it up that far into the plug. Can I leave it like this until the glow plugs actually fail? I know that there is a head job and a machine shop in my future, but I'd like to postpone it if possible.

If it isn't possible to leave it like this, then is anyone aware of a post on pulling the head?

Thanx

Here's a thread on the situation - http://www.peachparts.com/shopforum/showthread.php?t=109101&highlight=glow+plug+broken

Len

The way I remove the plugs that have carbon build up to is get them as loose as possible and flood them with Marval Mystery oil. It seems to disolve the carbon and I have always been able to remove them after a few days.

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1981 300D 147k
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1979 300D 234k (sold)
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I tried drilling them out but that was a PITA and it almost ruined the head when the angle went off a bit. I had a MasturBate tech remove the head and sent it to a machine shop and they told me that it costs more now that I have drilled it and they have to redrill and retap. After you get out of this fiasco, keep the plugs there and remove them ever couple of years. Also use anti-sieze on them. I did and had no problems. Also When the shop did the headjob at 60K, there wasn't much carbon buildup. This time when I did it 18 months and 60K later, the plugs came off like it should. I plan to do that in another 18 months.

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01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

Yeah I figure I will have to take it to a machine shop or pay someone to do the whole job. ugh. I'm not going to drill into the head myself - at least from the outside. I may try and do it from "inside" with the head off but I doubt it. How much was your machine job?

I thought I was being careful, the thing spun off so easily... Wonder though if anyone has run the car like that before? I read about someone finding a welded washer holding the GP in (one assumes someone found themselves in a position like mine) so it seems like people have. Mine are intact are far as their function goes - threads in place, working per the dash light. The head spins though... (as did mine ;-)

I buttoned the whole thing up and it runs. Seems a little clackier than it was before, but maybe I dislodged and electrical connection or vaccum hose went I had the intake off... Anyone run these things like this before?

You can't compare mine with yours. Mind was with the plug removed and having them machine it so the GP would seat right again. However, they told me that to take it out was about $75

__________________
01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

I know that Aklim and I have had completely different results and opinions with drilling out a stuck/broken glow plug, but for me it just wasn't that hard once I got serious with that plug. Lucky for me or unlucky for Aklim? Maybe, but if it happens again, depending on the access I have to the plug, I plan to try drilling it out again. But I hope I never have to do it again. My plan is to R&R the plugs once a year. I also use anti-sieze on the threads, but am not convinced that does any good.

Len
'99 E300TD 95,000 miles

I did mine in 18 months with no issues. No squeaking from the plugs. I used antisieze on them and coated the entire body less the tips. This was with 60K on the clock and there were no sticking issues. I'd say every 2 years would be good.

__________________
01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

Hi,

Same thing happened to my 95 E300D. I had them pull the head to remove the broken GP. Not a small job. But it's done and the car is running great. I just hit 171K miles on the odometer today. I plan to pull the plugs every year or two from now on.

Chuck

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