Help please - serious problem - need sugestions!

SgtAbn

New member
Hi Guys,

I have a serious problem and I am perplexed; any/all advice would be appreciated. My T4R will not run until this is resolved.

Situation:
1998 SR5 T4R with 265,000+ miles. I bought the T4R with 197K miles on it. The plugs & wires were allegedly changed by the previous owner.

I am changing the plugs and wires with NGK wires & NGK Platinum plugs ($10./each - ouch!). When I took out one of the spark plug wires that has the long ~6" tube on the end of it, some of the tube material (rubber? Silicone? Neoprene?) had dry rotted off and stuck around the base of the plug. Now I cant get a socket on it to unscrew it or remove it and I can't put the new or the old wire back on it and get it to fit tightly - even with the old wire there is a 3/8th's of an inch gap from it seating correctly. Obviously driving it like this would not be advisable.

Solutions I have tried:

1) I tried another socket to eliminate it was the socket's fault.
2) I tried vacuuming out the rubber/silicone/neoprene from the wire's shaft that was dry rotted onto the plug with a 5 or 6 HP (huge) shop vac - I bought a step down kit for the 2.5" hose to take the hose down to .5 inch or even 1/8". This gave it huge suction and fit down the shaft the plug was in = but with no measurable results.
3) My neighbor tried spraying ether or brake cleaning fluid down the spark plug shaft as he lit it with a lighter - a makeshift blowtorch in an attempt to melting and burning away the spark plug wire material. Which didn't work either.
4) I bought a blow torch and tried burning out the spark plug wire material that somehow dry-rotted to the plug / plug shaft and the problem here was that even though the blow torch will stay lit upside down, when I went to burn away the rubber the blow torch ignited a small flash fire 8" in diameter before I could even get it in the shaft and the flash fire sucked enough air out of the immediate area to extinguish the blow torch. I think this must be residue maybe fumes from item 3 above. In any case, I kept re-lighting the blow torch for thirty minutes and never got the flash fire burned out enough so I could get the darn torch down the spark plug wire shaft.
5) I tried putting so much WD-40 in the shaft that the rubber was submerged in an attempt to break down the rubber material.
6) At various times during this process I used a VERY long-necked pair of "L" shaped needle nose pliers (14"? made to take a hook out of a fishes mouth) to try to grab the rubber in the shaft - some came out but it was largely a exercise in futility. Approximately 40+ minutes were used on this cumulatively between all of the above attempts.

Solutions I have NOT tried:
1) Since the plug is still in tight, maybe there is another petroleum chemical such as gasoline to break down the rubber type material? ANY SUGGESTION'S ON WHICH CHEMICAL / PETROLEUM PRODUCT WOULD BREAK DOWN THE RUBBER/SILICONE/NEOPRENE
1a) AFTER #1 ABOVE = I FIGURED I CAN SHOP VAC OUT ANY LIQUID / DEBRIS SO IT DOES NOT GO IN THE CYLINDER AFTER REMOVAL.

MAJOR CONCERNS:
1) that any rubber type debris gets inadvertently knocked down into the cylinder upon re-installation of new spark plugs.

T4R friends-
I wrote a article on this website about the 3rd Gen not going into gear an I put my cell phone # out there as well. I have had a person approx. every 4 months call me on my cell asking for help resolving this transmission issue from all over the country- most of which were NOT members of this website and I have ALWAYS dropped everything I was doing and helped each and every one of them.

I am NOT a newbie- but I am also not as experienced as many of you. PLEASE HELP ME IN MY TIME OF NEED NOW THAT MY T4R IS NOT RUNNING AND THE LIBERAL ZOMBIE APOCALYPSE MAY COME ANY DAY NOW.

I am in Longmont, Colorado but my cell is 248-739-0482.
:ak472:
 
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Is the "nut" portion of the spark plug still in tact and can you see it looking down the spark plug tube? Or is there so much boot material left that you can't see it? Maybe post a picture for reference.

I'm kind of baffled. I don't think you can even remove the valve cover with the plug still in there. And of course it had to be the drivers side which is the bigger pain in the *ss of the two.
 
Take a long flat head screw driver and sharpen the end and use it like a knife/ scraper and cut/scrape the old material away from around the plug.
 
I would grab a pick/scrib with a pointed end. Or i would keep picking at it with needle nose pliers. The "X" style ones that multiple manufactures sell would work well for this since there is a confined space.
 
Take a long flat head screw driver and sharpen the end and use it like a knife/ scraper and cut/scrape the old material away from around the plug.

Yeah. I was thinking a pry bar. Try to cut and/or squash that stuff until you get it loose from the plug. Do it both as a tangent and radially. If that doesn't work, I'd hit it with a big. long 1/2" or 3/8" drill bit. I don't think the chemical approach will work. Neoprene is immune to gasoline, for example.

Eventually I'd get PO'd and take a 1" re-bar or similar and a BFH to the porcelain insulator. Pulverize it until nothing is left except the metal base of the plug. Trick is to avoid screwing up the valve cover in the process.

An impact socket or other tall socket will have a better chance of going on than a plug socket. Use a 1/2" drive and have something you can hook in the hole to get it back out in case you fail to get it on.

Ideal would be those old fashioned sockets that resemble a piece of pipe. But it might be hard to find one long enough.

Whatever you do, you need compressed air to clean out the hole after you break the thread loose and before you fully unscrew the plug.
 
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Had the same thing happen.

Take a wire coat hanger, cut it at a 45 degree angle (to get a sharp tip) and bend it into a small hook. The rest should be self explanatory. Took me a couple tries to snag it.
 
Is the "nut" portion of the spark plug still in tact and can you see it looking down the spark plug tube? Or is there so much boot material left that you can't see it? Maybe post a picture for reference.

I'm kind of baffled. I don't think you can even remove the valve cover with the plug still in there. And of course it had to be the drivers side which is the bigger pain in the *ss of the two.

For what it's worth, when I had this problem it took me 45 minutes to realize that there was still boot left on the plug. I thought that the nut had somehow sheared off or something when the PO changed the plugs.

Also, you can take off the valve cover with the plugs in without any problems however, you shouldn't have to.
 
For what it's worth, when I had this problem it took me 45 minutes to realize that there was still boot left on the plug. I thought that the nut had somehow sheared off or something when the PO changed the plugs.

Also, you can take off the valve cover with the plugs in without any problems however, you shouldn't have to.

If all else fails... the safest way to get to it and make sure its cleaned up right...

Valve cover gasket replacement time.
 
I'd see if you could get a couple of hooked pics in there to grab the boot and pull it out. I had a similar problem with the rubber insert in a spark plug socket coming out of the socket and staying on the plug so I couldn't get a socket onto the plug to remove it, but this was on a SOHC Honda engine so the plug holes are facing up and forward, much easier situation to work with than you've got. Good luck!
 
+1 with the coat hanger. I had to use such on a plug boot in a Honda once.

They make specific plug boot grabbing tools.

With your new ones, don't forget the dab of dielectric grease inside the boot.
 
This is what I would try. The rubber boot will act like the Chinese finger cuff if you remember that trick as a kid. Stick your fingers in either end of a tube and pull apart. The harder you pull the tighter it gets.

Same for the rubber boot. The harder you pull the tighter it will grip. Using a straw spray the top of the plug with WD40 and fill the rubber boot if possible. Then using a tall socket just slightly larger than the ceramic spark plug top and push down on the rubber boot. The boot will expand and let the WD40 seap around the plug. After a few compressions the rubber boot should release. Or you can try a socket that's slightly bigger than the rubber boot and try to twist off the rubber boot from the plug. The trick is getting the WD40 between the plug and boot. Then it will pop off and come out easily.
 
Update

Hi Guys

I am back at working at this problem today. I sprayed enough WD-40 in the hole to submerge the rubber on the plug overnight. Now I am going to shop vac out the WD-40 and try all of your suggestions.

I don't think I can take a picture that will help because the hole is so small and dark. Even in the daylight I have to shine a flashlight down the hole to see what I am doing.

I am absolutely shocked at howmany of you responded, all of you with valuable ideas - and you all responded so fast. I cant believe it. THANK YOU TO ALL OF YOU VERY MUCH. I will update this evening when I finish working on it.
 
I'd call local Toyota dealership and discuss the issue with them. Worth a shot. They may charge a lot $$ to get your problem solved with toyota undisclosed way, better than you trying yourself and make the issue worse.
 
I'd call local Toyota dealership and discuss the issue with them. Worth a shot. They may charge a lot $$ to get your problem solved with toyota undisclosed way, better than you trying yourself and make the issue worse.

LOL You surely don't belong here, the home of the DIY'r. What you said is sacrilege. Dare I say Heresy.

Move along now...:hello:
 
LOL You surely don't belong here, the home of the DIY'r. What you said is sacrilege. Dare I say Heresy.

Move along now...:hello:
Thanks for your criticism. I know my limit. When it comes something I don't feel comfortable DIY or ran out of options , I'd rather get help and get back on the road again. :drummer:
 
Thanks for your criticism. I know my limit. When it comes something I don't feel comfortable DIY or ran out of options , I'd rather get help and get back on the road again. :drummer:

I'm sure your mother told you at least once, "Ouki, you're capable of so much more."

Of course I'm just having fun. He'll be fine.
 

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