Glow Plug Removal and Thread Repair Kit, M8 and M10, 41-Piece

This 41-piece tool kit is designed for removing M8×1 and M10×1 glow plugs whose drive hexagon has broken off during an attempted removal.

The coordinated drilling, centring and extraction tools enable the remaining glow plug components to be processed and removed accurately.

Glow Plug Thread Repair

The included taps allow M8×1 and M10×1 glow plug threads to be recut and professionally restored.

Centring sleeves and a ball-bearing centring device guide the drills and taps accurately during the repair. The ratcheting tap holders facilitate controlled operation in confined engine compartments.

Cleaning the Glow-Tip Bore

Two long steel brushes are included for cleaning the glow-tip bore in the cylinder head after removal.

Removing carbon deposits and machining residue prepares the bore for the correct installation of the new glow plug.

Scope of Delivery

• 5 × taps: 1/4"×28 UNF, 12×28 UNF, M8×1.0, M10×1.0 and M8×1.0
• 4 × twist drills: 2.6, 3.4, 3.4 and 4.4 mm
• 3 × step drills for drilling out broken glow plugs: 4.4×7, 5.4×7 and 5.5×9 mm
• 2 × extraction bolts
• 2 × pulling spindles
• 4 × drill centring sleeves, 2.6–3.7 mm
• 3 × hex keys: 2, 2.5 and 3 mm
• 2 × round steel brushes: 5×300 and 7×300 mm
• 2 × tap holders with ratchet function
• 1 × centring device with ball bearing and pulling spindle
• 2 × spindle nuts
• 2 × twist-drill holders
• 1 × centring sleeve
• 1 × extraction sleeve
• 6 × twist-off sockets for glow plug electrodes: 2.6, 3.2, 3.5, 4.5, 6.5 and 8.25 mm, with 6.3 mm (1/4") internal square drive
• 1 × E10 socket with 10 mm (3/8") internal square drive

Removing Glow Plugs with a Broken Drive Hexagon

1. Select the appropriate twist socket and place it over the electrical connection of the glow plug. Turn it clockwise to shear off the wire pin of the heating element.
2. If the wire pin does not break off deeply enough, it can be drilled out as follows:
   • Slide the appropriate centring sleeve over the wire pin.
   • Carefully drive the centring sleeve as far as possible into the glow plug using a hammer.
   • Caution: The centring sleeve should remain protruding by at least approximately 3 mm to allow the drill to be positioned easily.
   • Use the appropriate drill to drill out the wire pin. The centring sleeve serves as a guide and centres the drill.
   • Remove the centring sleeve after drilling.
3. Insert the centring device into the glow plug bore.
4. Insert the appropriate drill into the drill holder and secure it by tightening the lateral grub screw with an Allen key.
5. Insert the drill holder into the centring device.
6. Clamp the drill holder in a drilling machine and carefully drill out the glow plug.
7. Secure the tap in the appropriate holder and cut a thread into the remaining part of the glow plug.
8. Screw the pull bolt into the glow plug using its long threaded end.
9. Remove the extraction spindle from the centring device and remove the spindle nut.
10. Fit the extraction spindle onto the pull bolt and secure it.
11. Insert the centring device into the glow plug bore.
12. Fit the spindle nut onto the extraction spindle and tighten it by hand.
13. Hold the pull bolt with a 13 mm wrench to prevent it from turning. Using a 30 mm ring spanner, turn the spindle nut clockwise.
14. Continue turning the spindle nut to gradually extract the remaining part of the glow plug.

Note: There is a risk that the front section of the glow plug may break off and remain stuck in the glow plug bore. A separate special tool set is available for removing this type of broken glow plug.