Broke bolt for coil pack?

[Am3gross]

Changed the plugs today in my 03 expedition, went well until I got to the last coil pack on the drivers side, was putting it all back together and snap, the damn screw broke. Was not even tight. Anyways my question? What do I do?

 

[stamp11127]

Easy outs - screw extractor. Get the set with the left handed/reversed drill bits.

 

[1997SCEBFEX]

did it break off flush? if not, can you use vise grips, or perhaps thread two or three nuts onto the stud so they lock on one another then unthread.

screw extractors too, but its a small bolt as i recall.

PanHandler.

 

[Am3gross]

did it break off flush? if not, can you use vise grips, or perhaps thread two or three nuts onto the stud so they lock on one another then unthread.

screw extractors too, but its a small bolt as i recall.

PanHandler.

That sum ***** broke clean off flush.... No chance putting anything on it...


I did make it out to lowes and bought me a new Dremel tool, a new 90 degree attachment tool, some small drill bits, and some other accessories for the cordless drill.... One way or another..... It WILL come out!


Now on the flip side the new plugs make a hell of a difference, truck starts easier and a lot smoother..

 

[toms89]

Changed the plugs today in my 03 expedition, went well until I got to the last coil pack on the drivers side, was putting it all back together and snap, the damn screw broke. Was not even tight. Anyways my question? What do I do?

Your screwed!!













Well.. try screw extractor as the others said but not sure how much room you have to work there. Dont know its possible to weld a nut to remaining portion to the screw?? Drill and tap but not easy to drill hard screw in soft aluminum intake. Worse case remove intake and repair/replace.

Or just let it float?!

 

[1997SCEBFEX]

i wonder if you can jb weld another bolt to it then try to remove it before you start the 'drilling'?
if it didn't work, you could dremel/grind off the residue & vacuum up.

if you have to drill it out, you'll have to tap the aluminum, then finding a bolt to fit the coil pack might be challenging too.

Like Tom said, if you let if float, perhaps commerical-grade double-backed tape, or velcro, but you'd have to use adhesive to withstand the temps.

PanHandler.

 

[Am3gross]

Ok here's an update....


Bought almost two hundred bucks worth of tools... I am in the same spot as I was before I spent that money on tools...

Bought a new wireless Dremel, been wanting one so that expense is ok by me... Bought the 90degree attachment for it.... It is to big to get in there.... Bought a flex hose, and a grab it bit.... Like said before drilling a steel screw that's in aluminum is not easy... Tried a regular drill bit and that did not work either.

So now... I let it float till I

a) have to worry about it
B) motor blows up and I need to take the motor out
C) I remove the intake
D) I go trade it in

Again as said before.... I am SCREWED!

 

[toms89]

Ok here's an update....


Bought almost two hundred bucks worth of tools... I am in the same spot as I was before I spent that money on tools...

Bought a new wireless Dremel, been wanting one so that expense is ok by me... Bought the 90degree attachment for it.... It is to big to get in there.... Bought a flex hose, and a grab it bit.... Like said before drilling a steel screw that's in aluminum is not easy... Tried a regular drill bit and that did not work either.

So now... I let it float till I

a) have to worry about it
B) motor blows up and I need to take the motor out
C) I remove the intake
D) I go trade it in

Again as said before.... I am SCREWED!

I'm sorry. It does suck!!

In similar situations I also have used a dremel before with abrasive cutting wheel on it and cut a slot in the top of the screw. This may cut some of the aluminum but this should not hurt if its restricted to the very top. Then use screw driver to remove. This will only work if it is not seized up in there.

 

[Jason_CPAPS]

If sezied hit it with map gas or propane. Be careful tho. Id prob drive that sum *****

 

[rex450se]

Use the Dremel to cut a slot in it then just use a flathead screwdriver to remove. It shouldn't be that big of a deal if you cut a little into the part surrounding the bolt. I've had good luck doing it like this.

Victor

 

[superexpy]

Use the Dremel to cut a slot in it then just use a flathead screwdriver to remove. It shouldn't be that big of a deal if you cut a little into the part surrounding the bolt. I've had good luck doing it like this.

Victor

Done this too!

 

[Am3gross]

Thought about doing this, but I thinki would have to remove the fuel rail that sits there... Honestly I am battling my laziness right now.... If I wanted it out I am sure I could get it out... But the truck runs and drives better then what it did before I started the job... I think I will jb weld another screw to the top of the intake and then just use a nut to tighten it down...

 

[sinacle1]

I did the same to mine about 4 years ago. I wound up squishing 2, 1/2" or 3/4" hoses cut to about 1" lengths with zip ties holding them together and zip tied them to my fuel rail over top of my coil to hold it down. I keep telling myself I'm going to fix it, but after 4 years, a tune up, and new coil packs it still works.

 

[98EXPY 5-0]

Since you've already done some "work" to it, this may no longer be an option. Take a centerpunch and a hammer and tap towards the outer edge of the screw at an angle and try to walk it around. I've done it with number 10 screws and it's worked great. Especially because it broke while installing and you said it wasn't tight (as aposed to siezed in the hole and broke on the way out).

 

[Cacique]

screw bolt #6 coil broke off and now broken intake

My 1998 Ford Expedition 5.4L Eddie Bauer SUV started misfiring. A few years back it had same problem and since had only replaced faulty ignition coils # 1 and 4 (passenger side). This time around I decided to buy all 8 "IGNITION COIL ON PLUGS" and all 8 "MOTORCRAFT SPARK PLUGS". As always, the most difficult side to do is the passenger side, coils 1 thru 4. After removing the air filter assembly, disconnecting a few hoses and lifting with a rope the ones I could not disconnect, followed by removing the two screws of the fuel line and lifting it out as high as possible with a rope line, I was ready to start. Removed and replaced all coil on plugs and spark plugs with no problems. Successfully put everything back together. Then went on to the driver's side to do the same on coils 5 (front) thru 8 (firewall). Cleared some hoses and did same with fuel rail. Coils 5, 7 and 8 came out without a hitch. Discovered that coil on plug # 6 was broken in two pieces. Was somewhat difficult to remove but finally did so. Inserted the remaining 4 spark plugs, then followed with inserting the "coil on plugs" to each. All screws tighten securely the coil plugs in place. However, coil on plug # 6 only went in partially in, leaving the coil on plug moving freely. MY grandson helped me through the process under my supervision of course as His smaller hands were better able to reach. I then jumped in to see what was the problem. I started tightening but the screw seemed to just spin until, SNAP! It broke off, leaving a stud out. I tried unscrewing it out with a vice-grip. Ended up just breaking the tip off. I then had to use my broken screw extractor kit but if failed. Drilled a hole in the center of the screw which finally went through it. I then used the extractor with no success. Decided to leave the extractor bit in place and try turning it with a vice-grip. Made it worst. The aluminum intake where screw goes into, broke off a piece. So now my only option is to just leave the coil in place dangling in place or buy a new intake. Gave up after 9 hours working on this. Tomorrow I'm going to attempt putting a screw through the coil on ignition with a washer and another washer in the bottom and tighten with a nut to see if I can tighten down the coil on plug. I'm crossing my fingers and hope it works.

 

[JDMarley]

Where can I get a new ignition coil screw for a 1997 Expedition? Can't seem to find a part number anywhere for 1st Gen.

 

[Hamfisted]

Where can I get a new ignition coil screw for a 1997 Expedition? Can't seem to find a part number anywhere for 1st Gen.

You know this is about an eleven year old thread right ?
The coil bolts are M5 x 27mm and you can get them on Amazon or eBay, or the dealer, or Home Depot, etc ...

Ford Coil Retention Bolts on eBay




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[Hamfisted]

Just for future reference ....
Pull the intake off. Spray some Liquid Wrench on the broken bolt. Use a left hand drill bit to drill a hole into the broken bolt. If it doesn't come out while you're drilling you can use an extractor in the hole to screw it out.

Left Hand Drill Bit Set on Amazon





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