Today, I wanted to at least start changing out my plugs on my 99 Expy 5.4L that has almost 102,000 miles. I didn't know if the plugs were ever changed because I bought it used with 82,000 miles on it.
First, thanks to everybody that has posted how-to's on the plug change procedure. It helped me to be prepared with all the tools I needed.
I realized after I removed the #1 COP that I had the wrong spark plug gap tool. Fortunately, Pep Boys is a 5 minute walk away.
Plugs 1 and 2 were pretty straightforward. Plug 3 was a little difficult to remove, but it came out eventually. In the past, I had gotten cyl 3 misfire codes. I looked at the boot of the COP and noticed some corrosion on the contact. I took the boot off and began to sand it to get a clean contact.
This is where my troubles began. I must have flexed it too much and the electrode broke off. #*%@. I called Pep Boys to see if they had the COP. Out of stock. I called AutoZone and they had 2 in stock. AZ is about 2 miles away, so I hopped on my bicycle to head over there. 1/4 mile into my trip, my rear tire went flat. I walked the bike back home. I rested for a couple of minutes and then took my wife's bike. 1/2 hour later I was home with a new COP. Of course, I forgot to put dielectric grease in the boot, but I'm not going to worry about that now. I unscrewed the bolt for #4 COP and got it loose but couldn't get anywhere. It's so tight in there, even with the hoses pulled off to the side. BTW, the plugs must have been changed at some point, because 1, 2 and 3 had Autolites in them. I decided to put the bolt for #4 back in and try for the other side. I took a look and decided it was for another day. It just looks so busy on the drivers side.
Anyway, I'm relaxing right now. I have 2 hours before I have to pick up my 2 1/2 year old from daycare.
Keith

 

Your a lucky man. I have to have the best story yet when I changed my plugs. A small screw from my alarm horn made a hole in one into #7 plug hole (unbekownst to me), and cracked my head and made engine go Kaboom! Insurance covered $4000 and I paid $1500 for a Ford remanufactured engine. Never again will I change those dang plugs.

 

what type off insurance did you have?

 

We have about 65,000 miles on our 99 5.4. I cant decide when to change them. I am dreading it. Maybe I will just make it a relaxed two day job.

 

Keith, that's a hilarious story....you and I must be related.

Good Luck.

 

Just take your time. I've done mine twice on my 97, even though it has wires, it still is pretty straight-forward. The worst one on mine is the passenger-side in the back. Had to use 12 inches of extension and a swivel to get to it. The more you do it the easier it gets. Then you won't have to ride the bike so much.

 

Today, I attempted the remaining plugs. I started by removing the power steering fluid bracket. COP and plugs 5 and 6 were a breeze. It took a while to get the right combination of extensions and joints to get to the bolt on COP 7. The plug was a lot easier to remove. COP and plug 8 weren't too bad. The only one I had left was the dreaded 4. My problem the other day was that I couldn't unplug the wire to the COP. I reached across the engine from a different angle today and I got the wire off. Then I had to deal with the right combination of extensions and joints again for both the COP and the plug. After everything was put back together, it started right up and runs very smoothly. Am I glad I don't have to do that again for another 60-100K.
Keith