Originally Posted By: 440Magnum
I'm amazed at the number of opinions against an impact, assuming this is an iron-headed Ford 300.
Personally, I WOULD use an impact (gently, in short bursts, and starting on the lowest air flow setting) before I'd tug on it with a breaker bar. If you have a small "butterfly" impact wrench, that would be the best option. I've broken FAR more parts with a breaker bar than I have with an impact wrench. Yes, its unnerving to realize you can't "feel" the part breaking loose, but you have to trust that short, sharp hammer-blow pulses of torque are simply less damaging than sustained high torque like you get from a breaker bar.
I have a couple of DeWalt cordless impact wrenches - a 3/8" and a 1/2" - that I use in just this kind of situation. The 3/8" is particularly useful as it can't generate enough torque to break a seized bolt, but it will often be successful in breaking it loose. I actually think of the 3/8" cordless impact as a torque limiter which is exactly what you want. Breaker bar? Not so much.
For a seized plug in an aluminum head, I'd spray a good amount of Kroil into the spark plug recess - enough so that liquid is visible - and let it sit for as long as it takes. You can drive the vehicle in the meantime. One week of Kroil will loosen anything. As soon as the plug is moving, alternately loosen and tighten until it comes out.