My 2005 CDI 2.7 L Sprinter engine had a glow plug that would not come out of the head. It un-threaded, but would spin loosely and only come upwards about 1/2". I tried needlenose visegrips to get it out, to no avail. Finally I decided to fashion a puller out of a 5/8" X 4" allen socket head bolt. (picture attached). To make the puller I measured the diameter of the glow plug just below the hex of the plug, and also measured the diameter of the hex points of the glow plug. Next I drilled the thread end of the bolt with the smaller diameter bit (about 1/2" deep). Then drill the socket head end of the bolt with the larger diameter bit (don't drill all the way through the bolt. Stop drilling about 3/16" from the end). Now thread a nut onto the bolt, make two perpendicular cuts lengthwise through the threaded portion of the bolt, all the way to the nut. I ran the nut down to the end of the bolt and heated the threads at the end of the perpendicular cuts in order to remove the heat treatment of the bolt. When cooled, run the nut fully onto the bolt and then slightly bend each cut threaded portion out from the center of the bolt. The four prongs should slip over the hex portion of the glow plug. Capture the nut with a wrench and unscrew the bolt from the nut. When the nut hits the head the glow plug should come out. I hope this makes sense to someone. Picture included below. A shoutout to DR. A for his help with this problem, and for being there for so many of us who need help. Tim
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