From the TSB:

Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.

 

Thanks a lot folks. I'm just shy of 110k (I know I should have done them already)...but no misfires, running and starting fine but lately fuel consumption has increased notably beyong my normal winter blend drop. I'm thinking it still may be prudent to follow the TSB procedure spelled out here in this thread. I'm feeling better about attacking it now due to its' build date, gonna check the boot color tomorrow to be sure. Thanks again.

 

If when you check the coil boot color its brown they will come out at any mileage like a regular plug should.
Here is a pic of the new plug and how much different it is. This is how they should have done it to begin with!
The one on the left is the new design you should have-

 

Some engineer had the idea of getting the tip way down into the mixture but didn't think of the consequences and Ford said "you're the engineer, lets run with it." Now the engineer is on vacation in the Bahamas with dark sunglasses while everyone is in misery over their plugs. Same old story. :-
Reminds me of the architects and carpenters; "Hey lets have the rafters end right at the edge of the outside wall" ........yea right.

 

All an engineer is supposed to do is just make everything fit. If you get mechanics designing vehicles, there would be so much less hassle on doing stuff and I'll bet less recalls.

 

Does Ford recommend plug replacement at 50,000 miles or around 100,000 miles on these newer engines? I've always done it around every 100,000 miles but others on here are saying 50,000 miles.

 

Official is 100k but I am seeing large plug gaps by around 60k so its up to you. Overall plugs are very well made nowadays and people go 150-170k on original plugs no misfires or driveability problem otherwise either.

 

Well there went my incentive, lol.

Btw, brown boots...thanks again. I can't wait to hoist my fat azz up and over to get at the rearmost plugs.

 

They might be sparking at 100k but they start deteriorating and losing MPG and power from day one. I change my plugs every 20K miles, plus I can keep an eye on them and the boots, not to mention junk gets in the spark plug holes. Some boots are well made nowadays too but they start falling apart the first time you wear them. (foot boots)................all boots.

 

Would re-gapping the plugs after X amount of miles help out?

 

Just my humble opinion. I would definitely replace the plugs with new rather than re-gapping the old ones. The reason being, it is not an easy job and it takes several hours to remove/clean/apply di-electric grease/ anti-sieze and replace. The cost of the plugs are not that much and the time invested is considerable.

 

No way if I am pulling plugs they are getting changed out. The old days of cleaning plugs re gapping and resetting are gone.

 

My 2005 F250 has 62,000 on it now. Do you think there will be an issue if I get it done now?

Regardless, I guess now is the best time I will ever have to try to avoid problems.

 

No, the gap is only a small part of the deterioration process, that would be like changing you auto trans oil and thinking it has a new lease on life,

 

More and more of these are not coming out nowadays and require extraction, allot more actually with age.