1996 Dodge Ram Spark plug removal

ivermcdriver · Posted at Mon Oct 26, 2009 2:25 pm

Engine Mechanical problem
1996 Dodge Ram V8 Four Wheel Drive Automatic 200000 miles

Hello, I have a problem with spark plugs (3 of them) all on the drivers side of a 1996 Ram with a 5.9L engine they broke off. Not the porcelain but they were so rusted the electrode with the 5/8s fitting snapped off. I got one out with a easy-out however the back two will not budge. Is their a way to remove the spark plug tube that goes around the spark plug.
Thanks

ramtough2001 · Posted at Thu Nov 19, 2009 10:05 am

I do not know how to pull the tubes. I ended up breaking them off (they break easily) right where they exit the head. I was hoping to pull them out and get a bolt remover around the round bottom ring of the plug, but I don't think removing them will even give enough clearance.

I have exactly the same problem. What appears to happen is that the washer is frozen to the head and to the remaining section of the plug. I have tried heat, freeze spray. penetrants, and ez-outs with no luck. Pulling the head seems to be the next course of action for me.

I was going to (carefully) try a hole saw in reverse to cut into that ring and maybe start it turning or at least loosen it a little so an ez-out will work. Let me know how you make out.

ivermcdriver · Posted at Thu Nov 19, 2009 2:53 pm

Hello ramtough2001,
I cut off tubes with dremel cut off wheel and it worked reel good then removed the brake booster (careful not to bend brake lines to far) then DRILL OUT what was left of the spark plug with a 1/2" bit, get a new one that will cut metal. It will be fairly easy to keep the drill at the same angle as the spark plug just pack the hole with a ton of greese. The washer will come out first real quick so watch for it then its removal of the old plug. Make sure piston is not at TDC before starting (I forgot after starting) Clear chips as best as possiable. Then you will have to re tap the head. All of this for a friends son!!! I took my time and cleaned over and over so no bits of metal got into piston chamber. Truck runs great now after having to be towed The spark plugs were never changed since new!! Best of luck with your truck

ramtough2001 · Posted at Fri Nov 20, 2009 4:16 am

Great idea! Thanks for the info. I will try this over the weekend. How do you get the ceramic section out of the plug before drilling it?

ivermcdriver · Posted at Fri Nov 20, 2009 1:28 pm

If the plug is still in the head put a socket on ratchet driver and turn till it busts off otherwise a small drift and hammer will take care of the ceramic stem.