Help! Coil separated in engine

[BobbySpeed]

2006 V6 Cayenne

I am pulling my coils to change them and the plugs. 4 out of 6 came out normally, 2 separated in the block.

It is deep and don't have any idea how to get the other half out since I can't reach it with a drill bit to tap them.

http://s441.photobucket.com/user/ctwith3/media/image-1.jpg.html

http://s441.photobucket.com/user/ctwith3/media/image-2.jpg.html

Edited February 3, 2014 by BobbySpeed

[clarksongli]

The issue you're going to have is the rubber boot inside the metal jacket is going to be "suction cupped" onto the spark plug.

Only though is to get a long hex bolt (the bolt head slightly smaller than the spark plug hole). Put A SMALL AMOUNT of JBweld on the head of the bolt and carefully smoosh it against the broken piece. Let it harden and then carefully twist and turn.

[BobbySpeed]

I knew it was the boot because I disassembled 1 of the 4 that wasn't a problem but I didn't think of a cold weld product. The snow doesn't help me getting to the store but I sent my sons out to shovel and I will dare to go to Homer's

[binger]

Hi Bobby,

You have two options.

1. Drill bit extension

http://www.lowes.com/Drills-Drill-Bits/Drill-Bits-Drill-Bit-Sets/Drill-Bit-Extensions/_/N-1z0yhr0/pl#!

2. Long drill bit.

http://www.amazon.com/DEWALT-DW1606-4-Inch-12-Inch-Extra/dp/B00004RGYN

[RacerX5]

Maybe some of these? GearWrench makes these as pointed needlenose, and a square tip needlenose. As usual, even though made in Taiwan, quality is excellent.

http://ecx.images-amazon.com/images/I/31DepuXVsCL.jpg

These things are pretty awesome, if there's anything to grab on at all, they can exert a lot of grip. They are specifically designed for grabbing something in very tight quarters.

[clarksongli]

from the pics it looks like it broke flush off....so it may not be possible to grip them with a set of pliers.....especially since the metal portion is so close to the plug wall.

my only question is do you think drilling a hole into them is going to help?

[RacerX5]

from the pics it looks like it broke flush off....so it may not be possible to grip them with a set of pliers.....especially since the metal portion is so close to the plug wall.

my only question is do you think drilling a hole into them is going to help?

Perhaps you can chip away enough material so you can pry the outer metal shield inward a little at one spot, and give you something to grab on.

[wvicary]

You can easily chip away that part of the coil, I've had them break before and used a steel punch and hammer to break away the remainder coil and then compressed air.

[BobbySpeed]

The issue you're going to have is the rubber boot inside the metal jacket is going to be "suction cupped" onto the spark plug.

Only though is to get a long hex bolt (the bolt head slightly smaller than the spark plug hole). Put A SMALL AMOUNT of JBweld on the head of the bolt and carefully smoosh it against the broken piece. Let it harden and then carefully twist and turn.

Thank you everyone for your help, clarksongli's JB Weld suggestion did the trick. I put an 11/16ths sockets on the bolt on the opposite side of the head of the bolt and packed the socket with paper toweling around the screw to keep it centered in the socket. The 11/16ths socket fits just right in the hole. After about 20 hours I just pulled it straight out with no trouble.

[clarksongli]

i'm glad the JB Weld worked out.