I just got my 00 excursion and was gonna change plugs. It has 104k miles on it and I took 1-7 coils out and when I went to loose #8 and bolt broke flush. Any good ideas for this solution?

 

I would get left hand fluted drills, the ones which cut counter clockwise, and drill it out.. The bolt may back out while your drilling it hence, the left hand drills. An easy out might work but, I would not want one breaking off in such a small hole. Great trouble then.
I have drilled out afew broken bolts although, not on my Ford. Use a center punch and get it right in the middle, centering the drill bit is crucial. Penetrating oil would be a good idea to use.
Thats how I'd roll.

 

Zedrive seems to speak from experience so certainly use his advice about this---sounds reasonable to me. Maybe also use a tap to clean the threads after removal, get a new bolt directly from Ford---about $5 each though.

Use a dab of anti-seize when re-installing too----can't hurt a bit and will prevent this from happening next time.

 

Easy as pie.

 

Is the bolt a ground for the coil pack or is it just for hold down?

 

I believe it is just a hold down. Also they only torque to 3-4 ft lbs.
BigPigDaddy posted up a better method if you got a welder handy. Either way patience will pay off.

 

Pick up the correct size easy out and the specified size left hand drill for the easy out. Center punch the broken bolt in the center and drill down far enough so the easy out can get a grip. The bolt will probably work its way out during the drilling process as Zedrive said. I remove broken bolts all the time with that method.

 

I drilled it and used a extractor and it broke off inside the drilled out part. So off to the shop it goes (lack of a welder to tack a nut on)

 

f- that, run it without the bolt. Use a little di-electric grease around the outside of the plug boot to assist holding it in.

 

Yeah---WTH you've got 9 other cylinders firing----no need to worry 'bout just one coming loose, losing contact and misfires! Screw it-----don't matter anyway!

 

it misfires really good with out that bolt in.

 

There is just something about mechanical advice that starts with "f- that" that makes me think twice. It's even more questionable when your avatar is an Audi emblem.





Just kidding with you p-nut!

 

it is a ground I had the same thing happen to the tee. I made a small bracket and bolted it to the valve cover stud works great. I can post a pic if you like

 

Abosolutely just kidding-----but it does make me ask how many of those "professional mechanics" at the stealerships and lube 'n rob quicky oil change places utter that same thing from time to time?

Then again change the rear shocks on an E van and F-That comes to mind repeatedly!