Trouble with COP hold down bolt

nyuk98gt said:

89lxsport50:

I don't have COP's but I will tell you what I would try to do. Call or visit your local Ford dealer and ask if they have a kit to fix the insert. I suspect that this is not an uncommon problem (lots of threads on various boards).

If you want to fix it yourself, I would try a Dremel to grind or cut off the head of the bolt. That will let you get the COP pulled. Then, attack the remainder of the bolt with Vice-Grips to pull the insert up (with Vice-Grips) into the plastic of the intake. Once the insert is snug, put a drop of PB Blaster penetrating oil on the threads and try to remove the stub by turning it with Vice-Grips (smallest size). If the insert stays in the intake then you can use a toothpick to apply epoxy glue into the bottom of the hole, then push/tap the insert down, and apply a tiny bead of epoxy around the top of the insert. Let it cure for 24 hours. Use a tap to clean the threads of any epoxy that has strayed in there.

If the insert turns again, you are better off just pulling the whole insert out. Once it is out, you can remove the bolt stub by any means you wish (more PB Blaster, put the stub in a vice, and unscrew the insert using pliers or Channel-Locks and a gentle squeeze. Once the insert is free, test fit a new bolt. Butter the insert with epoxy and push it into the hole. Let the epoxy cure for 24 hours. Chase the threads with a tap.

That's all I got, lol. Hopefully, somebody who has fixed this (properly) will reply. My method is just to give you something to think about.

Chris

***edit:

See Post #5 in here:
http://www.stangnet.com/mustang-forums/708709-spark-plug-change-little-problem.html

***end of edit

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