GlowPlug Connector Hell -Boots frozen - Diesel Forum - TheDieselStop.com
6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

 
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post #1 of 10 (permalink) Old 06-14-2019, 01:23 PM Thread Starter
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Unhappy GlowPlug Connector Hell -Boots frozen

Every connector in the drivers side (4) broke when trying to remove.The remainder of the rubber boot still in the engine frozen to metal. Can't pry them out. Got one out with some careful drilling, but the other 3 are pretty much inaccessible with a dremmel or drill. Haven't tackled the passengers side except to verify they too look frozen and ready to break.


What to do?

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post #2 of 10 (permalink) Old 06-14-2019, 01:52 PM
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Taking the wheel well liner out (and the wheel off) improves access.

Mark
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post #3 of 10 (permalink) Old 06-14-2019, 01:55 PM Thread Starter
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First thing I did when I started the tear down. Still not enough room. I have ordered a flex attachment for the dremmel, may be I can chew them out with it.

hdude

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post #4 of 10 (permalink) Old 06-14-2019, 04:50 PM
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Can you (carefully) melt them out? A small propane torch may do the trick. Enough heat to soften them may allow you to dig the remnants out with a suitable tool.

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post #5 of 10 (permalink) Old 06-14-2019, 05:18 PM Thread Starter
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Using 4" wood screws, I have been able to get the plugs out of the drivers side. 2 plugs on the passengers side came out with 18ga wire. #1 & #3 broke and need to be drilled and screwed. ugg.

hdude

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post #6 of 10 (permalink) Old 06-14-2019, 05:33 PM
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Quote:
Originally Posted by klhansen View Post
Can you (carefully) melt them out? A small propane torch may do the trick. Enough heat to soften them may allow you to dig the remnants out with a suitable tool.
Two things that I have seen help: Liberal amounts of penetrant oil and let soak. Then use a heat gun to soften things up.

Unfortunately you were well past that stage before the thread stared (or so it seemed).

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post #7 of 10 (permalink) Old 06-14-2019, 06:51 PM Thread Starter
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Got the last two out. They were actually easy compared to what was on the driver's side. Buggered one of the ports (2nd one I drilled) but doesn't seem to be in the area that the o-ring sits. I know more when I can get a bore scope camera on it and hone it some. It's 107 outside, so I am stopping now. Pulling the plugs and compression tests in the morning.

hdude

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post #8 of 10 (permalink) Old 06-15-2019, 10:38 AM
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The boots go thorough rocker box tasks valvecover off push back though that's what I did if I'm remembering right.
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post #9 of 10 (permalink) Old 06-16-2019, 03:20 PM Thread Starter
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Don't try this at home.

Don't try this at home.

Using a drill where you cant' get close to straight and even tell what you've been destroying. As I mentioned, successfully drilled other ports with a dremel using a debur bit (3/16") that was about 1.5" long. Best to drill at a angle across the rubber from above or below the wire: and maybe 3/4" max depth. Screw in a 3" or 4" screw and find somewhere you can get vise grip around with some leverage and then Pop.

Nothing to debur in the port it doesn't look like metal flakes enter it.. Maybe coat with some hi-temp sealer and let cure before replacing the harness.
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hdude

2006 F350 Lariat CCab Dually FX4, 205K, Bilstein 5100s, EGR Delete, BPD Cooler Relocate, BPD WaterPump, Coolant Filter,

Upgraded BlueSpring and easy to fix common failure points.

Last edited by hdude; 06-16-2019 at 05:52 PM. Reason: Clarity
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post #10 of 10 (permalink) Old 06-18-2019, 08:57 AM
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I had the same problem with 3 out of my 8 GP's. I used a flexible inspection camera to monitor as i drilled into the snapped off boots with an angle die grinder and a small drill bit. As was mentioned before, I drilled them at an angle to ensure I had enough material to have the pry tool bite into the boot. They all came out with no issues other than i actually drilled too far into one of them and my bit went into the block about 1mm. This freaked me out but it's been ok so far. Thankfully the block is a little thicker than 1mm 😉

I think the die grinder had too much power and just pulled the bit into the boot pretty quickly. If I had to do it over again, I'd use a slower speed dremmel to ensure slow penetration into the boot.
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