I am hoping someone has a solution besides taking off the heads. The mechanic that is working on my truck has broken off the spark plugs while trying to replace them, is there any way to get the rest of the spark plug out without taking the heads off which will cost 1500 dollars? Should I have to pay for this?
Go back through the forums on this site this is a well know problem and there is a tool to remove the ground shield from the head but it is not readily available that I know of also ford has a TSB out on how to remove these plugs but that will not help you at this point. You may have to go back a bit here to find the right forum but it is here. If you are out of warranty I doubt ford will help you even if you are at a ford shop this issue is going to get bad before it gets better!!!
I thought I read that there was some special broken spark plug remover tool Ford supplied to dealerships because of this issue. This tool is available to the general public as well, no?
edit- FX4 Lineman, I was typing as you were posting
We were on the same page at least, feel bad for some of these guys this is really bad PR for ford, I am gettng ready to take mine to the dealer and have it done before I run out of warranty in case they mess it up??? L8R
There is a special tool...made by Rotunda. Its called a "spark plug removal tool". ONly needed if the plug breaks off in the cylinder head.
Do a search on ebay. I ordered mine from Rotunda but the ship date kept getting pushed back due to being back ordered. I ended up getting on one ebay.com
Its about $130 bucks. Look up the TSB on this website....follow the instructions! The trick is to loosen the plugs 1/8th turn and use penetrating oil to break up the carbon build up.
Since you've already had a plug broken off....the special tool from Rotunda is designed to remove the broken off spark plug stuck in your head. Beats having to remove a cylinder head.
I believe the second extract tool approximates the rotunda tool that is being used by dealers. That first one looks interesting. It's a sad state of affairs when so many companies are making products to deal with this issue that is being ignored by Ford. Champion is also making new one piece plugs. These companies put some serious money into R&D to make these products, and their market analysis has shown that these products will pay off...and Ford goes on ignoring it.
The dealer will more than likely say you have to pay. There are a few posts were it seems the dealer did the right thing, but by and large it seems many try and get the customer to pay for pulling the heads or an hour of labor per cylinder.
Ford refuses to acknowledge this MAJOR problem that MANY of us are having. They said in a personal email to me that until the National Highway Traffic and Safety Administration makes them, they will continue to ignore it.
Please go to https://www-odi.nhtsa.dot.gov/ivoq/ and file your complaint so maybe one day with enough of us complaining, it will force them to fix this quality problem in their trucks.
Hmmm, thanks for th link, but I really hate filling out forms, and I've already replaced mine (twice) and my wifes once, and I already have the tool. And is it really a safety issue? I really think that form is for airbags that accidently deploy and kill children. Or brakes that fail, and kill nuns crossing the street. Not plugs that stick when the car is parked...in a garage...with the COPs removed...
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