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Old 05-10-2011, 05:14 PM   #1
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Still cant get tube out..

Hi Guys,

bit of a SOS here, I still can not get my split spark plug tube out. I have taken the spark plug out, cleaned and dried the tube, put my one inch boat plug in, tightened right up (even made a special socket to go over the handle in order to be able to tighten it right up with a ratchet and then attempt to pull it out with a fork shaped lever...

The result? Bent handles on the boat plug and eventually, the plug coming out without the tube....

Can anyone suggest another alternative? How much does the Porsche tool cost?

Regards,
Sam

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Old 05-10-2011, 06:05 PM   #2
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the boat plug didn't work for me either as my plug tubes seemed fused to the engine after 90k miles.

so I made a very simple tool to pull the tubes out, which worked for me.

it consists of a large carriage bolt (about 7 inches long, with a large washer at the end of the bolt sandwiched between two nuts. I actually got the idea from my local porsche shop after asking whether there was a special tool to remove them. they had made their own tool, which I copied (very loosely). I inserted the long carriage bolt with the washer at the end of it inside the spark plug hole after removing the plug. while holding one end of the bolt, I used the other side with the washer to grab onto the end of the plug tube to yank it out. In other words, you are using the washer to grab the end/edge of the plastic tube to pull it out. it's a bit hard to desribe.

I think what you're encountering is the resistance created by the o-rings that are around the plastic tube which probably get hardened or fused after being in service for so long.

I'll try and take a picture of the crude tool I made after a run to the hardware store...
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Old 05-10-2011, 06:10 PM   #3
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I think I follow. Just putting the washer end through the spark plug hole and pull the tube out there? Is there some sort of lip I can get onto between the tube and the cylinder head? Obviously dont want to be pulling on the thread of the cylinder head!!!

Appreciate a picture if you find time. Cheers,
Sam
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Old 05-10-2011, 06:44 PM   #4
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I believe there is basically a gap between the edge of the tube and where the tube sits in the plug hole, but it's been over 2 years since i did this (i was replacing my tubes since I had some good leaks coming from the spark plug holes).


I was skeptical too when they showed me the crude tool they had fashioned. So I very carefully used my homemade tool and didn't use too much force. when you drag the washer you can feel it catching on the edge of the tube. You shouldn't be able to hit the spark plug hold threads because the washer would be too big. of course, be careful not to let the nut or washer fall off into the engine. I'm sure others with more mechanical experience than I will chime in!
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Old 05-11-2011, 10:14 AM   #5
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A long time ago I was a plumber and I remember pipe test plugs similar in concept to the boat transom plug but a litte more heavy duty. Graingers sells several sizes. Don't know if they will work or not.

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Old 05-11-2011, 10:36 AM   #6
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Go to any auto parts store and ask for a Brake Shoe Spring hook tool, works everytime.

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Old 05-11-2011, 03:57 PM   #7
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Cheers guys - will see what I can do this weekend!

Sam
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Old 05-12-2011, 06:01 AM   #8
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I found the transom plug didn't work well for me either - couldn't tighten it up enough and it just slipped out without the plug. I used 1" rubber mandrel from my drum sander kit and it worked perfectly.
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Old 05-12-2011, 06:25 AM   #9
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I just used a socket with some electrical tape around it to thicken it up. Good luck
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Old 05-12-2011, 01:10 PM   #10
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if you're replacing the tube, just use a screwdriver. stick it into the side of the tube & pry. they pop right out.
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Old 05-12-2011, 02:57 PM   #11
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Cheers guys - will try.

Yes - I am attempting to replace all 6 with new tubes and o-rings that I have ready to go, just cant get these bastards out!!!

Sam
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Old 05-24-2011, 08:19 PM   #12
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Hi guys,

just thought i'd let you all know that I eventually got the troublesom tube out. Only replaced that one so far as it took me bloody ages to get it out! The tool I made (as per suggestions) got a great hold of it, but still wouldn't pull the tube out.

I had to resort to priying it out with a flat blade screwdriver which was still not easy by any stretch. I think the previous owner may have applied some sort of sealant on the o-rings instead of engine oil....

Anyway, its out now - will tackle the other 5 shortly.

Thanks for all your help and assistance!

Regards,
Sam
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Old 05-25-2011, 03:00 AM   #13
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sam -

these actually work the best. you'll be able to pop the tubes right out.

http://www.harborfreight.com/4-piece-heavy-duty-pry-bar-set-1654.html

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