I've got a 2008 SD 4x4 5.4 engine. I bought it used--haven't replaced the plugs yet----have bought new Autolites to go in it. Does the 16 valve 5.4 in the 2005-Up have the same problems with plugs as the previous years? I'm an old Ford Tech who worked at a dealer during the 70's. We had some same type trouble with the old Y-block engines where the plugs hadn't been changed in years. Our solution was to take a can of freon with a can tap and hose, have the engine still warm, spray the plug with the freon and it would come out. Have you guys ever heard of anyone trying this on the modular engines? My truck still runs great, but I don't know how long the plugs have been in it. Before I tackle the job, I just wanted to weigh all the options, thanks, Dennis.

 

Congrats on the new truck!

There have been a couple issues in the Superduty era (1999-present), pre 2005's didn't have enough threads in the head and some of the earlier ones would spit plugs. In 2005 with the introduction of the 3valve engine (so you actually have a 24 valve), they have the opposite problem, the plug sticks and can break. The main cause is the plug is a 2pc design and w/ the carbon fouling, the bottom end of the plug can stick and separate.

The good news is, you MAY not have any of those issues, 2008 was the year they got that fixed, if your engine was built after 10/9/07 then you should be fine. I believe the tell-tale sign of the new design is brown coil on plug boots. If they're still black then you might have issues.

If you do have the 2pc plugs (and they've never been changed) then you should do some research. Ford put out a TSB (#08-7-6) on procedures and there's a a tool from Lisle that reportedly works very well if you break one. You can get that for $60-70 on Amazon.

Either way I'm sure it won't be a big problem for someone w/ as much wrenching experience as you. Take a look and if you still have the old plugs I can send you a copy of the TSB.

 

Maverick22, we purchased a 2009 F-250 with the 5.4 in it back in April. Will this engine built in the '09 model year have the plug problem solved. If so would an average guy with average mechanical aptitude (like me) be able to change out the plugs on the improved design heads if our '09 in fact has those improved heads.

 

The 2009 model year shouldn't have this problem.

 

Brown COP means no plug breakage issues, black COP would be the two piece breaker, '08 was the changeover so it could be either. Seems like the SD's always are the last to get the updates so it wouldn't surprise me if you had the two piece design.

NVM, missed that previous post addressed it.

 

Agreed. I don't know any of the specific idiosyncrasies for the later engines but the plug breaking won't be one of them.

 

Maverick22---Thanks for getting me straight on the 2valve--3valve engine. I sure hope my has the later built engine---I'll check the color on the coil boots soon as I can. What did you think about using freon on the plug when trying to break it loose? My truck has about 110K on the speedo--still runs great at all phases---maybe the plugs have been changed correctly once already, I hope.

 

Your 24 valve 5.4L engine should be fine. Just keep an eye on how it runs over the next 20k or so. If it starts missing, then you know you need to change the plugs. Follow the TSB and you will be OK.

 

I would stick with motorcraft plugs but that's just me.

 

From what I have read, it is a lot more than just you!

 

Even with the bit older 5.4's (05-07) we should assume by now, most knowledgable owners have installed the newer 1 piece plug like myself. And yes Motorcrafts all the way.

 

+1 on Motorcraft

+1 on 1 piece plug

Not so sure on assuming it was done. As long as it was working......

 

Seems to be the ONE thing people seem to read in the book is the 100K mile plug interval, I wouldn't expect them to every be changed. Nice of Ford to knock it down to 90K in these later years

 

Got around to checking the coil boots on my truck----has the brown ones---that's good news----engine was built after 10/09/07----truck was built 02/2008 at Kentucky plant--downloaded TSB 08-7-6----will use procedure anyway----Thanks guys for the imput!

 

I guess the freon probably wouldn't hurt anything, but I'm not sure it's necessary. Don't know how deep the cold could work it's way in and contract the metal. If the previous owner followed the scheduled maintence guide then they should have already been replaced, hard telling though. You might go to your local dealer and have them pull an Oasis report on the truck to see what work had been done to it.

Great news! Can't hurt anything to use the TSB and be more cautious, good news is you shouldn't have to worry about the special tool.