BIGSERT® TRITON REPAIR

This kit will fix ford heads with a straight section between the threads and taper seat. Models can be 1.9, 3.8, 4.6, 5.4, 6.8 liter engines. (click here for inserts type)

Please note all orders shipped to New Jersey and New York will be subject to sales tax for customers who are not tax exempt.

SPARK PLUG REPAIR KIT P/N 5553

1 55511 Wrench   1 55512 Reamer   1 55513 Tap   1 55514 Driver   1 55515 Setting tool   1 55516 hex key 1/8   1 55518 Triton Counterbore   1 51487 hex key 3/16   1 6020 Sealer   5 51459 Triton Inserts Z-tech inserts not included order separately if needed p/n 51460 Or use kit p/n 5554 (click here for spark plug types)

click here for video instructions 33mb divx player needed for playback www.divx.com Note: The above video is on a section view head, optionally right click and save to desktop.

INSTRUCTIONS

Stop: Check that the valves are not open!

The only 100% way to know the valves are not open is to remove the valve cover and inspect the cam, making sure that it is not depressing the valves on the damaged spark plug hole.

Possible work around: this is a 2 man job

Have someone turn the engine over by hand with a 18mm socket from the front of the engine. Turn the engine over until it is going up on the compression stroke. Place your thumb at the top of the spark plug hole at the same time to block off the air.When you feel the engine compression stop pushing air against your thumb the piston will be top dead center. Turn the engine a little more to be on the down stroke, both valves should be closed at this point, and the piston should be out of the way.

PAGE 1
Using the wrench provided, tighten the set screw to secure the counterbore in place. Counterbore the hole to the full depth permitted by the tool P/n 55518 picture A: until the counterbore bottoms out on the hole and spins freely. NOTE: Some engines will require more metal to be removed with counterbore tool than others (e.g. Romeo 2001 and up 1L2E heads) read here for more info. TIP: Packing the flutes with grease will help to catch stray chips from going into the cylinder. Place the Reamer into the square of the wrench and tighten the setscrew to secure the reamer in place.
Ream the hole picture C: until black "Stop Collar" touches head. This will creat the 45 degree countersink seen in picture D: When you start getting close to the stop collar coming in contact with the head, you will want to clean the chips from the reamer so you will have a positive stop on the head without having any chips interfering. The reamer should spin very freely when the collar touches the head.
	3. TAP THE HOLE Tap the hole with the wrench provided. There is a pilot at the front of the tap to help guide it straight into the hole. Use contact or break cleaners to thoroughly clean out any remaining chips and oil.
Mechanics Tip 1: Packing the flutes with grease will help to catch any stray chips from going into the cylinder. Mechanics Tip 2: Using a shop-vac with a thin hose taped to the nozzle is helpful removing any remaining chips in the cylinder.
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4. Setting Tool A: Screw the setting tool into the insert B: Lightly tighten the socket cap screw
Using the wrench provided place the setting tool into the wrench Place the Lock-tite around the middle of the insert and into the clean prepared hole Screw the insert into the hole until the flange of the insert is seated into the head. This is approximately 20 foot pounds.
Hold the wrench, and in a counter-clockwise rotation, untighten the cap screw with the allen key provided. This will allow the setting tool to release itself from the insert. You can now remove the setting tool from the insert.
5. INSERT THE DRIVER TOOL Using the wrench provided, place the driver tool into the square and tighten the setscrew to secure the driver in place. Oil the bottom threads of the insert driver with a few drops of driver oil. optionally you may use 30wt motor oil to oil the driver tool.
Screw the driver into the insert. The driver will cold form the last few threads of the insert. While screwing the driver into the insert you will feel the driver start to tighten up, with a little more power continue through the insert until it loosens up. Remove driver, repair is complete.

When our company opened on October 1st 1993, our mission statement became a way of life for us. Our passion for performance enabled the company to offer a nationwide 3 year unlimited mileage warranty unheard of in the industry. Imitation is the sincerest form of flattery, so when some companies followed suit, we knew we had set a benchmark for excellence and customer service. By 1994 Promar Engines had grown to 72 employees. That same year New Jersey Business News Magazine named Promar Engines one of its top 25 fastest growing companies in New Jersey.

The PERA has awarded Promar Engines "Engine Rebuilder of the Year 2003". We take great pride in participating with organizations such as: The BBB, AERA, PERA, AAIA, AJE, AJA and APRA.

Here at Promar Engines we continue to reach new levels of customer service while offering consumers a wide range of services:

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Promar Engines is located in the original facility at 10 Peach Street in Paterson, New Jersey.

We know that in this industry consumers have many choices. We want the opportunity to prove to you our commitment to excellence. Once you have chosen Promar Engines for your automotive needs, you will become our greatest testimonial.

If you have any questions, please feel free to call toll free Monday-Friday 8am-5pm EST @ 1-800-422-6022 or local @ 1-973-684-1500.