newer 5.4 spark plug problems
 

I've just heard the late 5.4 engines are having a problem with their spark plugs welding themselves to the aluminum heads. Anyone know of a way to prevent this? How much does a Ford dealer usually charge to replace 5.4 engine spark plugs? I heard it is real expensive.

I'm surprised no one has commented this as I gather it's a potentially serious issue if they have to be drilled out (by removing the cab?!)....or maybe I'm not using this forum properly and have missed the replies to this thread. Anyways, I bought my '04 F-150 5.4L in July '11 and only later learned about this standing issue with those engines. I understand you should remove and service the plugs every 50Kms/30Mi. Everything went well when I had mine serviced last year. My truck now has 176,000 kms on it and I'll be checking/replacing the plugs again at the 200,000 Km mark unless I learn otherwise before then. HTH.

Thanks for the info. Road Ranger. Did you change your plugs yourself or did your dealer do it?

Well capttwb, I had the dealer do it because of that stomach-sinking feeling when I break something and have to do the job twice and for twice as long! Unfortunately, I don't remember how much that cost because there were two or three items done during the same service visit. I've been told that it's hellish expensive if one of those plugs breaks, something in the $1,500 range?

Do a search, this has been covered many times. There is a tool that can remove most broken plugs. The new plugs are one piece and don't break in two. 04-07 are the problem years.

There's a TSB out on this too. Make sure you warm the engine SLIGHTLY before you remove the plugs. If they don't break loose under "normal" tension hit them with some blast off or comparable, (Ford makes one for this) and let it do its work. Look at the bright side. If you snap them off and worst case scenario you have to remove the heads.....You'll have new head gaskets! }>

Awriiiight !!! Now I feel better about any potential spark plug issues. Thanks, guys.

I did mine at 195000 Kms and every plug broke. I knew of this problem and bought the Lisle tool kit ahead of time. It takes about 10 minutes per plug to extract the broken pieces. I sprayed the plugs with carb cleaner and let it sit 24 hrs. You want to make sure that you don't use too much torque removing the plug. It is possible to damage the aluminum threads. Also, Aluminum is softer hot and I wouldn't do it with the engine hot

There are a handful of YouTube videos if you are interested

Thanks Jeremy.:-jammin

So how about the 4.6 engine? (2004-2007) Same problem?

4.6 engines do not have the plug problems, only the 5.4

My understanding is that it is the 3 valve engines and the 5.4 is more of a problem than the 4.6