04 5.4L 3V Spark Plugs broken in head...

wisecountybuck · #1 (**permalink**) 07-04-2009, 05:05 PM

I've heard don't waste my time on the removal tool (is this true???). Other than taking it to a shop, is this my only option? I have 1 plug out, 3 broken and haven't touched the other 4 (including the hardest one's to get to...)
The F-150 has 100K miles and now I know I should have replace them a long time ago because of the seizing issues. Just sent an email to Ford but don't really expect much to come of it. On the part where they wanted to know my specific question, I asked them to point me to a Chevy or Toyota dealer for my next truck purchase latter this year...
Oh yeah, thanks for having me on the site.

bridge · #2 (**permalink**) 07-04-2009, 06:27 PM

Welcome. Did you follow the TSB and allow them to soak? Guess it doesn't really matter now, does it? I've heard that the tool does work. However, there is more than one tool and each is preferred depending on where the plug breaks and whats left in the cylinder. Search around here and you will find some pretty detailed threads on how to get the rest of them out of there. Good luck!

wisecountybuck · #3 (**permalink**) 07-04-2009, 06:47 PM

I didn't know there was any issue or TSB so no I didn't read anything...
Have seen several threads and heard about a do it yourself tool but can't find it. If I can't fix it tomorrow it will have to go into the shop Monday morning.
For the other plugs, what do I soak them with? WD 40? Some other oil? Any ideas will help.

firstonraceday · #4 (**permalink**) 07-04-2009, 10:41 PM

On a cold engine (which yours will be) loosen the plug 1/8 - 1/4 turn. Use Motorcraft Carburetor Cleaner (latest TSB) around the spark plug letting the fluid fill up to the nut on the spark plug. The earlier TSB recommended Kroil and I've heard of some using PB Blaster. Let the solvent wick down past the plug to break up the carbon (you'll probably want to let it wick down for an hour or more with 100,000 miles prior to continuing with the plug change). Then slowly work the plugs out (probably working them back and forth a few times) to get them out. Work slowly.

If using Motorcraft plugs for replacement, coat the shroud at the bottom of the plug with nickel antiseize prior to installation. Champion makes a one piece plug for this application, part # 7989.

BTW, Ford made a design change to the cylinder heads of the 3V engine around November 2007 to eliminate the problem.

tylus · #5 (**permalink**) 07-04-2009, 10:58 PM

here ya go. This is the route I personally would go before dropping $100 on the Lisle or Rotunda tool

(courtesy of effects4)

Quote:

Originally Posted by effects4

3/8 x 16 coarse threaded tap
1 foot section of 3/8 x 16 threaded rod
4 pack of nuts..although you only need 3
1 washer

anything smaller will not grab, anything bigger won't fit in the hole without risking damage.

all the sockets I used were 1/2 inch drive, starting with a 1 inch deep socket.

you only need to tap in about 2 threads. I used a socket and duct taped it to an extension so it wouldn't come off in the plug hole.

wisecountybuck · #6 (**permalink**) 07-04-2009, 11:30 PM

Thanks for the info.
So I'm assuming I tap this contraption into the ground plug with the 2 "upper" nuts and back out with the "bottom" nut?

tylus · #7 (**permalink**) 07-04-2009, 11:43 PM

use the 3/8x16 thread tap and cut a few threads

then

thread the entire assembly into the newly cut threads (top jam locked nuts)...then tighten down on that lower nut to push against the washer/sockets and extract it

wisecountybuck · #8 (**permalink**) 07-05-2009, 12:06 AM

Tylus
Thanks a ton for this. I can do this!!
I will get the tap in the morning and probably have the rest of the parts. Even though Motorcraft has a replacement, I will go with the Champion 7989 plug. Just because Ford has really pissed me off now...
Thinking about a Yota next. They know how to design and build vehicles...

Djack04F150XL · #9 (**permalink**) 07-05-2009, 12:11 AM

Wisecountybuck, I had the same problem with mine last November. I would recommend soaking them overnight and get the Lisle 65600 tool kit. It has a pusher tool to push the porcelain deep enough in the heatshield to tap the puller tool and remove the plug heatshield. It does a very good job. Tylus' tool may work but the Lisle tool has guided sleeves to keep the pusher and puller straight. Even with these tools you must use PATIENCE. I learned the hard way.

spatts · #10 (**permalink**) 07-05-2009, 12:29 AM

Here is an Idea .........
How about all the members here chip in $1.00 and we will buy all the tools needed to do this job. All we have to do is just keep shipping them to each member as needed . Even better Yet just have every 5.4 liter Ford owner send E-mails,Letters,Phone calls ect..... to Ford and demand a Mother F----ing Recall and end this Bull Sh-- once and for all.

wisecountybuck · #11 (**permalink**) 07-05-2009, 12:54 AM

Quote:

Originally Posted by spatts

Here is an Idea .........
How about all the members here chip in $1.00 and we will buy all the tools needed to do this job. All we have to do is just keep shipping them to each member as needed . Even better Yet just have every 5.4 liter Ford owner send E-mails,Letters,Phone calls ect..... to Ford and demand a Mother F----ing Recall and end this Bull Sh-- once and for all.

Now this I could go for.. I'm not one to sue anyone but this has me pissed!! I don't understand Ford coming up with this design at all. Even being a dummy, I could tell you this was a bad design. Wish I would have checked out the design of this truck 100% (that's not my responsibility so I didn't...).
Mix/matching metals and two piece spark plugs is asking for disaster... A little of what we in Texas call "commen sense"...

And the window motor/regulator is stupid also along with the plastic parts of the front grill. Can't keep it from rattling hitting any bump in the road...

Seriously, Chevy or Yota may be my next truck so a bailout maybe in the near future for Ford,,,

ChargersFanInCO · #12 (**permalink**) 07-05-2009, 10:19 AM

Quote:

Originally Posted by wisecountybuck

Now this I could go for.. I'm not one to sue anyone but this has me pissed!! I don't understand Ford coming up with this design at all. Even being a dummy, I could tell you this was a bad design. Wish I would have checked out the design of this truck 100% (that's not my responsibility so I didn't...).
Mix/matching metals and two piece spark plugs is asking for disaster... A little of what we in Texas call "commen sense"...

And the window motor/regulator is stupid also along with the plastic parts of the front grill. Can't keep it from rattling hitting any bump in the road...

Seriously, Chevy or Yota may be my next truck so a bailout maybe in the near future for Ford,,,

Feel free to buy a Chebby or a Toy, but you're not going to get anyone else around here to talk crap about Ford. The spark plug issue is actually a small problem compared to the other trucks out there. Drop the tailgate on a Tundra and sit in the middle of it if you weigh over 200lbs.

Ryan50hrl · #13 (**permalink**) 07-05-2009, 10:28 AM

I know it sucks to break plugs.....but really if you think about it....this is a rather minor problem now that the tools exist to fix it quickly and cheaply....and if for one minute you think toyota, dodge, or chevy don't have similar problems elsewhere....just might i remind you of the dodge trannies, toytoa tailgates, and numerous other "small issues" that every brand has....

Try engineering something with thousands of parts without a problem....good luck...

wisecountybuck · #14 (**permalink**) 07-05-2009, 04:11 PM

Thanks for all the help/guidance on this project. Got it all fixed!!

I take it I can't bitch a little about Fords? Is this site just for lovers of Ford trucks that can't/won't/aren't allowed to complain a little?
This is not my first Ford truck and probably will not be my last either. But in the heat of fighting this issue, and the heat of doing it outside in Texas in the summer, I might complain a little...

So sue me...

wisecountybuck · #15 (**permalink**) 07-05-2009, 04:16 PM

Quote:

Originally Posted by ChargersFanInCO

Feel free to buy a Chebby or a Toy, but you're not going to get anyone else around here to talk crap about Ford. The spark plug issue is actually a small problem compared to the other trucks out there. Drop the tailgate on a Tundra and sit in the middle of it if you weigh over 200lbs.

Actually I have read many post on this site "talking crap" about Ford. I've bitched about my wife and/or kids before but that doesn't really mean I'm getting new ones from another "dealer"...