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    Ford 3V Broken Spark Plug Tools – Review

    Calvan 39100DennisB © Summary: We’ve sold many of the the Lisle 65600 broken spark plug removal tools for extracting broken plugs from Ford 3 valve engines. I’ve even demonstrated the use of the Lisle tool out in the field and it worked well. Over the years we have had pretty good feedback on the kit. However some of the problems with the kit can be troublesome. The Lisle method uses a different approach than Rotunda (the Ford way). Ford says to remove the broken porcelain first by loctiting a pin inside the center of the porcelain where the electrode rod was. For these reasons we have taken a second look at the Calvan 39200 and 39100. The vehicles affected have Ford 3 Valve engines from 2004-2008 Ford 4.6 and 5.4 also with 3-Valves that have spark plugs which are M16 x 1.5. The spark plugs look similar to the Champion 7989 when they are in one piece.

    Once the pins are loctChampion_7989ited into position, a puller is used to remove the broken porcelain. Then a tap can be used to make threads inside the electrode shield. Then the puller and puller housing is used to remove the remainder of the broken plug. With the Lisle method the porcelain is not removed. It is forced deeper into the electrode shield to allow enough room for the self tapping puller screw to be used. In most cases this works great. If the porcelain breaks and a piece falls into the cylinder there’s a problem. Also we have had some customers report back saying the puller screw only worked on a few plugs and became too dull to bite into anymore shields.

    With the Calvan 39200 and 39100 the method is the same as Ford recommends. The Ford method does not call for pushing the broken porcelain down further – the 39200 removes the porcelain, getting it out of the way, therefore eliminating the possibility of any pieces falling into the cylinder where it can cause damage. And since the 39100 is NOT self tapping. It uses a tap first before the puller screw is used; the puller screw will not get dull over time (or sometimes after a few uses) like the Lisle tool. So in conclusion, by using the Calvan 39200 and 39100 much of the risk is eliminated like the possibility of breaking the porcelain and it falling into the cylinder. And the possibility of the threads wearing on the puller screw is eliminated since the tap makes the threads instead of relying on the Lisle self tap method. When ordering the Calvan kit be sure to get both the Calvan 39200 and the 39100.

    Related Tools

    Lisle 65600

    Calvan 39200

    Calvan 39100


    Comment from Dennis Bandy
    Time August 27, 2013 at 10:15 pm

    If you are just looking for the replacement puller screw because yours is worn and not grabbing now, see the following link – Replacement Lisle Puller Screw.

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