JET H3659 (01) PDF DOCUMENT

The JET H3659 is for all 3 valve Triton engines, from 2004 to present.

CAUTION: DO NOT REMOVE PLUGS WHEN THE ENGINE IS EXTREMELY HOT OR COLD. DO NOT USE AIR OR POWERED TOOLS FOR PLUG REMOVAL OR EXTRACTING. BE SURE TO ALWAYS WEAR SAFETY GLASSES.

The JET H3659 kit is used for a “Mode 2” breakage. This is when the porcelain center and ground electrode breaks off in the stainless steel shield and both parts are left behind in the cylinder head. The kit is used to extract the broken porcelain first, so that the H3661 Ford Triton Spark Plug Shield Extractor Kit can then be used to remove the remaining pieces.

CAUTION: DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND ELECTRODE SHIELD AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. ENGINE AND BONDING ADHESIVE MUST BE AT AN AMBIENT TEMPERATURE OF 70°F (21°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. DO NOT REUSE THE ONE TIME USE EPOXY PINS. THIS ENSURES SURFACE CHARACTERISTICS FOR BONDING.

The JET H3659 kit contains: 1-Epoxy Applicator with Guide, 1-Epoxy Electrode Applicator and Extractor Assembly (one time use electrode applicator pin, end nut, threaded shaft, guide, washer and jam nut), and 1-sampler tube of bonding material (Loctite® #680). Optional replacement adhesive can be Loctite No. 638 or Loctite No. 426.

NOTE: DO NOT APPLY ANY BONDING MATERIAL DURING THIS INITIAL STEP.

1. Remove any remaining electrode material from broken porcelain using long nose pliers.

2. Spray a quality parts cleaner fluid into porcelain hole for 2 to 4 seconds.

3. Insert the H3659-11 Epoxy Pin into the H3659-12 End Nut onto bottom end of H3659-16 Center Screw and tighten to lock in Epoxy Pin. Be sure to keep the Epoxy Pin as centered as possible when tightening. Insert complete assembly into H3659-13 Guide.

4. Retract the adapter and pin completely into the guide to protect the Epoxy Pin. NOTE: A DAMAGED OR BENT PIN WILL PREVENT INSERTION INTO THE PORCELAIN.

5. Insert the assembly into the spark plug well and insert the pin into the porcelain hole.

6. Spray metal parts cleaner for 2 to 4 seconds between the Spark Plug Well and the guide. Lift guide slightly to allow fluid to flood plug well.

7. Pull threaded rod up and down, cleaning the inside of the porcelain with the cleaning fluid. Be sure to not disengage the pin and porcelain.

8. Repeat process 6 and 7.

9. Remove Extractor assembly and flood Spark Plug Well again with metal parts cleaner, then completely blow out the entire Well and porcelain with dry compressed air.

10. It is important to be sure all parts of assembly and Spark Plug Well / porcelain are clean and dry for proper bonding.

NOTE: DO NOT ALLOW THE BONDING MATERIAL TO CONTACT THE SPARK PLUG THREADS IN THE CYLINDER HEAD.

1. Working time limit of the bonding agent is short, no more then 10 minutes. (This is not the cure time.)

2. Apply the bonding material to the H3659-10 Epoxy Applicator, approximately 3/4″ (19mm) long. Do not apply excessive amount of epoxy that can drip off the applicator.

3. Insert the H3659-10 applicator into the porcelain and move up and down approximately 1/2″ (12mm). Twist the applicator to completely cover the inside of the porcelain.

4. Remove and apply additional epoxy to H3659-10 applicator and repeat steps 2 and 3.

5. Clean the H3659-10 applicator with metal cleaner before epoxy starts to bond to the shaft.

6. Reassemble the main porcelain extractor tool with a new H3659-11 pin assembly.

7. Apply a generous amount of epoxy to the pin (Do not allow to drip off pin) and retract pin assembly into the guide.

8. Insert completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread bonding agent.

9. Repeat steps 7 and 8.

10. Leave assembly to set and bond for 1 hour before attempting to remove.

11. Install the washer and nut to the end of the threaded rod and finger tighten.

12. Hold the end of the threaded rod with a wrench and tighten the nut until the porcelain is free of the ground electrode shield.

If the pin does not successfully cure and remove the porcelain, repeat the process using a clean pin, dry and clean porcelain and prevent the threaded rod from rotating during removal process.

You can now use the H3661 Electrode Shield Extractor Kit to complete the process of removing the remaining broken spark plug pieces.

If the broken porcelain cannot be extracted with the H3659 Extractor Kit, the recommended repair is to remove the cylinder head to extract the broken spark plug by other means.