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Old 07-13-2015, 10:01 AM   #1
nhlblues
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1996 ford escort: Spark plug removal

I want to remove the spark plugs but unable to loosen them. Any tip as to how I can easily loosen them up without breaking them?
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Old 07-13-2015, 06:48 PM   #2
denisond3
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Re: 1996 ford escort: Spark plug removal

They may have been over-tightened, but basically turning them counter-clockwise is what has to be done. I use a 5/8" deep socket wrench, with a 3/8" extension and my 3/8" ractchet on the end of that. You may need to slip a length of pipe over the ratchet to give you enough length to get a lot of force for loosening them. I use a 6 point socket, rather than a 12 point socket.
If the ceramic part of the plug cracks, at least you would have the plug out.

For the #1 plug (the one closest to the passenger side of the engine), its not easy to get an extension on a socket on that plug, because the alternator and a.c. hose is in the way of a direct access. You can buy an extension called a 'wobble extension', whose square end is slightly barrel shaped. This lets the extension be at an angle of up to 15 degrees from straight, and will make removal/re-installation of the #1 plug much easier. I use a pair of extra long needle nosed pliers to reach the plugs after they are unscrewed, to get them out of the 'pockets' in the head.

Its possible the plugs have been in there long enough and tight enough that there will be some 'galling', where a piece of the aluminum threads sticks to the plug. This can cause damage to the threads inside the head as you unscrew the plug. Unfortunately there isnt any good way to prevent that if it happens. For future help, you can buy a spark plug thread tap, to use for cleaning up the threads inside the spark plug holes. A small amount of aluminum shavings or carbon may fall into the cylinders, but it isnt likely to cause any damage. It will just be blown out when the engine is started next time.
If the 'galling' happens, you would want to use new spark plugs for sure. You should coat them with a slight amount of an anti-seize compound rubbed onto the threads when you reinstall them. This will prevent any galling in the future.

It is rare, but taking plugs out where a lot of galling takes place can result in a spark plug thread hole that wont take a spark plug and let it be torqued up' i.e. the plug would be turning in stripped threads. There isnt any easy way to cure this with the head on the car. There are kits you can buy to let you drill out the old spark plug holes and install a helical steel threaded insert. While that can be done with the head in place on the engine, it involves more aluminum shavings falling into the combustion chamber, enough to -possibly- cause a problem with some damage to pistons and piston rings. But like I say - its only with a very badly galled spark plug hole. Its not a common problem.
It wont really help to squirt penetrating oil into the spark plug holes, until the plugs have been loosened at least 1/4 turn. Then spraying plenty of WD-40 or similar product into the plug holes might make it easier to get the spark plugs out without any damage.
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Old 07-13-2015, 11:24 PM   #3
nhlblues
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Re: 1996 ford escort: Spark plug removal

Thank you for all the helpful information. I will give it a try and hope I don't run into any difficulty.
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