DenLorsTools.com Summary: Solution for the problem of how to remove a spark plug insert that fell into the cylinder of an engine. Ford spark plug blowouts and how to repair using a spark plug thread repair kit are one of our most covered topics here at DenLorsTools.com and at our sister site WiseAutoTools.com. One question we’ve had several times recently is “what do you do if a Lisle or Sav-A-Thread insert threads down all the way into the hole and drops into the cylinder?” Ouch, that’s a scary thought, was our first reaction. (We also had a recent customer drop a tap from a parts store kit into the cylinder). Having to pull a head just to get a thread insert out is not an easy pill to swallow. After we thought about it for a moment… hey there is a way to get it out without removing the cylinder head!

Using the Time Sert 5600 kit which has the largest outside diameter insert will open up the hole to approximately 3/4″. If the insert that fell down into the cylinder is steel and can be picked up with a small telescoping magnet. It may still be a tight fit, but with a little patience and holding your mouth just right, this can definitely be done. In fact a recent customer was so happy when this worked, that he made a phone call back to us to let us know that he had good news! After reaming the hole which is one of the first steps, after making sure the valves are closed; He said he had to position the Lisle insert just “so” and twirl the magnet a little so the insert could come out through the newly reamed larger hole. But hey, he got it out. Then he was able to tap the new threads and install the triple oversized insert and finish up with the Big Sert which is the double oversized insert which accepts the original size spark plug.

If the insert that fell into the hole is not steel and therefore cannot be picked up with a magnet, perhaps mechanical finger type retrieving device can be used with the assistance of a video inspection camera. A lot trckier no doubt, but well worth the attempt before jumping in feet first and pulling the head.

See the Time Sert 5600 Triple Oversized Spark Thread Repair Kit for more information on how the kit works. Also check out the video that I made using this exact kit below (and on the product description).