Spark Plug Repair Kit - Repair Damaged Spark Plug Holes

Engines

Engine Kits

Components

Please choose what type of product you would like to search

Need a spark plug repair kit? We have 2 great kits to choose from below

BIGSERT® TRITON REPAIR KIT $450

Part No. 5553

This kit will fix ford heads with a straight section between the threads and taper seat. Models can be 1.9, 3.8, 4.6, 5.4, 6.8 liter engines. (click here for inserts type)

	1	55511	Wrench
	1	55512	Reamer
	1	55513	Tap
	1	55514	Driver
	1	55515	Setting tool
	1	55516	hex key 1/8
	1	55518	Triton Counterbore
	1	51487	hex key 3/16
	1	6020	Sealer
	5	51459	Triton Inserts
Z-tech inserts not included order separately if needed p/n 51460 Or use kit p/n 5554 (click here for spark plug types)

click here for video instructions 33mb

divx player needed for playback www.divx.com
Note: The above video is on a section view head, optionally right click and save to desktop.

INSTRUCTIONS

Stop: Check that the valves are not open!

The only 100% way to know the valves are not open is to remove the valve cover and inspect the cam, making sure that it is not depressing the valves on the damaged spark plug hole.

Possible work around: this is a 2 man job

Have someone turn the engine over by hand with a 18mm socket from the front of the engine. Turn the engine over until it is going up on the compression stroke. Place your thumb at the top of the spark plug hole at the same time to block off the air.When you feel the engine compression stop pushing air against your thumb the piston will be top dead center. Turn the engine a little more to be on the down stroke, both valves should be closed at this point, and the piston should be out of the way.

PAGE 1

Using the wrench provided, tighten the set screw to secure the counterbore in place. Counterbore the hole to the full depth permitted by the tool P/n 55518 picture A: until the counterbore bottoms out on the hole and spins freely. NOTE: Some engines will require more metal to be removed with counterbore tool than others (e.g. Romeo 2001 and up 1L2E heads) read here for more info. TIP: Packing the flutes with grease will help to catch stray chips from going into the cylinder. Place the Reamer into the square of the wrench and tighten the setscrew to secure the reamer in place.

Ream the hole picture C: until black "Stop Collar" touches head. This will creat the 45 degree countersink seen in picture D: When you start getting close to the stop collar coming in contact with the head, you will want to clean the chips from the reamer so you will have a positive stop on the head without having any chips interfering. The reamer should spin very freely when the collar touches the head.
	3. TAP THE HOLE Tap the hole with the wrench provided. There is a pilot at the front of the tap to help guide it straight into the hole. Use contact or break cleaners to thoroughly clean out any remaining chips and oil.
Mechanics Tip 1: Packing the flutes with grease will help to catch any stray chips from going into the cylinder. Mechanics Tip 2: Using a shop-vac with a thin hose taped to the nozzle is helpful removing any remaining chips in the cylinder.

PAGE 2

4. Setting Tool A: Screw the setting tool into the insert B: Lightly tighten the socket cap screw

Using the wrench provided place the setting tool into the wrench Place the Lock-tite around the middle of the insert and into the clean prepared hole Screw the insert into the hole until the flange of the insert is seated into the head. This is approximately 20 foot pounds.

Hold the wrench, and in a counter-clockwise rotation, untighten the cap screw with the allen key provided. This will allow the setting tool to release itself from the insert. You can now remove the setting tool from the insert.

5. INSERT THE DRIVER TOOL Using the wrench provided, place the driver tool into the square and tighten the setscrew to secure the driver in place. Oil the bottom threads of the insert driver with a few drops of driver oil. optionally you may use 30wt motor oil to oil the driver tool.

Screw the driver into the insert. The driver will cold form the last few threads of the insert. While screwing the driver into the insert you will feel the driver start to tighten up, with a little more power continue through the insert until it loosens up. Remove driver, repair is complete.

Here's the second Spark Plug Repair Kit

TIME-SERT® REPAIR KIT $210

Part No. 4412E

Inserts sold separately

Screw Thread Inserts American and Metric Sizes

TIME-SERT® are threaded bushing inserts, used for the refurbishing of stripped and damaged threads.


	TIME-SERT® is a solid bushing insert. This guarantees easy installation and allows for full load use of tapped hole, ensuring protection against stress and vibration.

	TIME-SERT® is thin walled due to synchronized internal external threads. Thin cross sectional area allows for installation in areas of limited space and clearance material.

	TIME-SERT® is self-positioning. Having a flange on the top of the insert will insure that the insert will have positive placement and cannot wind down into the newly repaired hole.

	TIME-SERT® is self locking. On installation the bottom internal threads of the insert are cold rolled to expand the mating external threads into the base material locking the insert in place.

HOW TO REPAIR DAMAGED SPARK PLUG HOLES

The repair of stripped out spark plug holes are easy to fix, with the TIME-SERT® Spark Plug repair kits!

KIT CONTENTS

1. Wrench
2. Step-Tap
3. Insert Driver
4. Seat Cutter

Inserts sold separately

- WARNING -
Cutting tools may shatter if broken. The wearing of safety glasses is required in the vicinity of their use.

Start the step tap into the hole to be repaired keeping as straight as possible.

Use the wrench provided, place wrench over tap and tap new threads. Continue to tap through until the cutting edges are approximately 1/4 inch below surface.

Leaving the tap 1/4 inch below the surface ensures that the seat cutter will not hit the back of the tap flutes.

Leave the step tap in the hole. Place the seat cutter over the shank.

The seat cutter does two operations. First the seat cutter will cut the countersink for the flange of the insert, then it cuts a new seat for the sparkplug washer.

This operation is the same for the taper seat inserts.

Using the wrench rotate the seat cutter. After a few turns lift the seat cutter to inspect the seat. Repeat operation until the seat is completely cleaned up. Remove the step tap from the hole.

Good Seat Complete	Bad Seat Incomplete

Make sure the hole is clean and dry. Lubricate the driver tool with Time-Sert driver oil. Screw the insert onto the prepared hole.

If doing deep hole repairs:
Lubricate the driver tool with Time-Sert driver oil or 30wt Oil. Screw the insert onto the driver then into the prepared hole.

Using the wrench provided rotate the driver into the insert. When the insert is seated the driver will tighten up. With increased pressure continue to rotate the driver through the insert until it loosens up. Then back the driver tool out of the insert.

Note: Taper seat inserts
These inserts are silver plated and require sealer p/n 6020 on the outside of the insert.

- Section View -

Repair is complete. Solid steel threads are square to the reconditioned seat, insuring a good spark plug seal.

info@promarengine.com

Email us for website design and development.