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Broken Plug 200 1978

If what you are saying is that the threaded end is all that remains in the head (no ceramic left at all) you may be able to install a screw extractor into the hollow threaded shell. The most effective type are the ones marketed by Snap-on. They consist of a set of round bars with ribs running the length--this is the part that gets inserted into the "drilled to specific size" broken bolt-stud-or spark plug in your case. A hex "nut" (with grooves to match the ribs on the bar) slips over the bar. This is what you apply a wrench or socket to. These sets are expensive so you may need to have this job done by someone who has the proper size kit. I think I'd give the remains of the plug a good direct whack with a flat ended bar to hopefully "loosen" the threads. The plug may have been crossthreaded--or maybe it's a too long of a reach plug whose threads were left exposed inside the combustion chamber and has a coating of carbon now (common problem with air cooled VW Beetle motors that used a short reach plug but had the wrong plugs installed).
I definetely feel for you. The '80 245 I bought 10 years ago had 123k miles. I decided to treat it to a new set of plugs---1,2 and 3 came out no problem--4 turned a few degrees and locked up. I didn't want to deal with stripped threads or a broken plug so I left it alone--and put the other three back in to keep it company. It's working on reaching 270k now. In a worst case scenerio you may need to change the head (not such a bad job and maybe less work than repairing what you have). -- Dave






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