I would go after the Dealer with the kit to remove broken plugs they should not have 7 broken plugs they cant get out thats crap was the guy a apprentice
how many miles on you truck just had mine done 76,000 klm. none broken
Dealer has done over 20 no heads pulled but some broken plugs removed with there special tool
don't let them screw you over
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2004 xlt 5.4 Supercrew
Goodyear wrangler S/A P255/65/17 3.55 gears
Ford bug shield and window shades Crome step bars
and Leer cap
i am a mechanic by trade and just did my truck and my brothers I used the tsb, loosening plugs 1/4 turn and soaking with penetrating oil for 30-50 minutes and had no breakage on 16 plugs. they all came out just fine with around 52000 miles. a couple were kinda hard but didn't break. A ford mechanic shouldn't be breaking plugs if they have half a brain and read the tsb. I wouldn't be paying no bill for them breaking the plugs.
Part of the problem w/ these plugs is the fact they are supposed to be 100,000 mile plugs, so most will wait until 100,000 miles or more to change them and that's when breakage occurs. Changed mine at 70,000 miles and had no problems, and that's without reading the TSB
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2005 F150 XL 5.4L ext.cab,longbed 4x4
Volant w/ ram air intake,Magnaflow catback duel exhaust, 3" Bushwhacker flares, Eagle alloys(7 lug rims), BFG All Terrain T/A's, JVC KD-NX 5000 W/ nav, dvd, Sirius, am fm cd w/ 12 disc changer, chrome w2w nerfs, Xcal ll Troyer custom tunes
I can see one or maybe two breaking but not seven. Sounds more like the mechanic didn't know what he was doing. A mechanic at a Ford dealer should know better, especially in light of the TSB on spark plug removal. Even if they break there is a kit designed to remove the spark plugs without removing the heads. The dealer should have been on the phone with you after the first on or two broke not after they broke seven.
I was aware of all the issues with the plugs from reading all the other posts on this site and the TSB so I took my truck in early (82K). My Service Writer called me when the first one they tried to remove broke. But after breaking one what are you supposed to do? Tell them to just replace one and zip it back up? I plan on keeping this truck for a long time so we had to continue.
The second came out fine then 3 and 4 broke. The fourth one (furthest back on driver side) could not be removed with Ford's special tool they designed to remove the broken plug so I was told the head would have to be removed on the driver side. And since all four broke on the passenger side and they had to remove the driver side head anyway that they would remove both heads; that's it's not much work to remove the second if you have to take one off.
there is still something wrong here you have 82000k mine was 76000k difference 1 oil change should not have 7 broken
bad mec.
sorry to here you got this screwing
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2004 xlt 5.4 Supercrew
Goodyear wrangler S/A P255/65/17 3.55 gears
Ford bug shield and window shades Crome step bars
and Leer cap
it can be more than just the mechanic though i would think... how that vehicle was driven can also play a part i assume.... how much carbon build up etc... i did mine at about 55,000 miles and i broke #4 and 6... followed the tsb to the letter, except i let the oil soak for prob 6 hours
I agree that it is possible the Ford mechanic either does not know what he was doing; did not follow instructions for spark plug removal; or rushed the job. A vehicle owner should not be responsible for the workmanship of the mechanic or a design flaw in the sparkplug. Fight them on this one. I took my truck to Troyer performance to have it dyno tuned. While I was there they changed my plugs and said 2 broke no problems; it took them no time at all to do this the plugs looked horrible. They told me that after 35,000 miles you start losing performance because the plugs are starting to wear and the reason why Ford and other automobile manufactures claim the plugs do not need to be changed until 100,000 is so they can claim a low cost of ownership which looks good on the JD Powers report.
I just took my '05 FX4 in for a plug change. I wanted to have them changed while still under warranty. The truck has 34,000 miles on it. I've been running the Edge Evolution tuner on setting 3 (performance) since the 1st 500 miles using high octane gas. I went to spark plugs dot com and bought a set of 8 single-piece Champion plugs:
8 - Champion Double platinum
Stock Number: 7989
Part Number: 7989
Unit Price: $18.99
Extended Price: $151.92
The local stealership changed out all plugs for $209.00. In the process they managed
to break the 2 front plugs (one per side). So even though I was using good gas
and mostly freeway driving, there were still problems. So my cost was $151.92 for
plugs + $209.00 for the change = $360.92 out the door. I guess this isn't too bad
given that 2 plugs broke.
yeah i'd say u did pretty good... i broke 4 and 6 on mine... thought about ordering the removal tool (which i should have done before i changed the plugs) but decided not to and borrowed my buddy's tow truck and took it to the local ford dealership, picking the one i figured least likely to rip me off... i gave them the 2 brand new plugs and got them to pull the broken ones and put in the new ones. $600 later, not even removing the head. the service manager calls me 3 HOURS later to tell me it's done and when i pick it up they are charging me 4 HOURS labor!!! not going by the book or anything cuz i'm sure the book does not quote 4 hours to change two plugs, broken or not. she had no explanation as to how he did 4 hours of work in 3 hours, refused to change my invoice and when i asked for the manager, she said she was the manager... so to make matters worse, 3 weeks (2000 km) down the road my truck's misfiring. so i pull plug 6 out and sure enough those ...kept my plug (or broke it) and put one in that has no electrode left, looks like it's got 150,000 miles on it. i called the dealership and she said "there must be something wrong with your truck that did that to the plug b/c we would not do that" and hung up on me!!!!! i just left it alone, i have no time and didn't want to aggrevate myself anymore. sorry for the long post but i had to vent to someone
I trust you have filed a complaint with FOMOCO, and the General Manager of the dealership. False work orders,using used parts is a very serious offense. I would not stand for this for 1 second. No screaming or yelling I would just send a letter documenting these issues to Dealer G.M and FOMOCO customer service. IMHO.
i haven't done anything... like i said i just haven't had time - dude i work like 120 hours a week when we're busy... and i really didn't know who to complain to
It frost's my #ss when dealerships use the advantage that they have plenty of time and money to blow off the poor working stiff like you and me! If you look in your manual it has the #'s of who to contact at Ford. I would make copies of the invoices and highlight the time in,time out to show the issue of hours charged. Second photograph the "suspect plug" send that to both Ford and the Dealership. If your claims can be verified, no legit business would ever want to get involved in this b/s. Don't let these scumbags ... We work too hard for our money! OK i've calmed down, good luck.
Last edited by IB_Tim : 05-13-2008 at 05:05 PM.
Reason: F##k you!
well...as dadirtydog says, I got off lucky with the $209 charge from the stealership. It took them 8 hours from the time I dropped the truck off until it was ready. At the time the service manager said it would be $209 regardless of how many plugs (if any) broke. I just hope the Champion plugs work out. So far, with only a few hundred miles on the new plugs, I don't notice much if any difference in the way the truck runs out....we'll see how it goes. On the up side, at least now I can change the plugs!
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3.55 gears
2005 F150 XL 5.4L ext.cab,longbed 4x4 
