Concerned about spark plugs
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Senior User
Joined: Jul 2004
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Concerned about spark plugs
04 FX4 - I believe I have read all the posts about the spark plug issues. Last time truck was in the shop for warranty work I asked them to take a plug out and confirm they were fine. They told me everything was OK. The manuf date on the door says 10/03 and I only have about 1,500 miles until warranty is up. What do you guys think I should do? I don't want find out I have an issue when I go to change the plugs myself, but I don't want to pay the dealer to do it either.
Senior User
Joined: Dec 2005
Posts: 361
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From: Lexington,SC
You are talking about the 5.4l 3v engine ? Ford now has a TSB out. On a warm engine;warm to the touch. Spray each plug well with a aerosol lube specifically for
easing rusted/siezed threads. Wait 10-15 minutes,then remove plugs. The article I saw showed 8 plugs removed ,all plugs had rusted electrode covers.
The threads looked fine. Ford DOES NOT recommend anti-sieze on the threads.Coat the electrode cover with a nickel based anti-sieze compiund.
It's enough of a problem that Ford has a plug removal tool for plugs that fail during removal.
easing rusted/siezed threads. Wait 10-15 minutes,then remove plugs. The article I saw showed 8 plugs removed ,all plugs had rusted electrode covers.
The threads looked fine. Ford DOES NOT recommend anti-sieze on the threads.Coat the electrode cover with a nickel based anti-sieze compiund.
It's enough of a problem that Ford has a plug removal tool for plugs that fail during removal.
New User
Joined: Oct 2006
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Is this plug thing a big issue? I own a garage and just had a plug removal fail. Threaded part came out but plug stayed in. It was towed to local Ford dealer( that had spaecial tool) to remove. Now they want $1800.00 to remove and change plug. This is a 2004 F 150 with 85000 miles. What a bunch of crap. We are calling costomer service to try and remedy this. My costomer has 8 of these trucks. I bet he will NEVER buy another FORD product again
Elder User
Joined: Jun 2006
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From: Fuquay Varina,NC
The problem is not with the threads, its the smooth part above it that gets siezed in the cylinder head. $1800 is a rip off, you used to have to R&R the head to get the old plug out, but there are specific TSBs and tools that ford has FOR THE SOLE PURPOSE of removing pieces of spark plugs from the 3v heads.
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Posting Guru
Joined: Sep 2005
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From: Oxford, CT
oh well, i applied the anti-seize on the threads when i replaced mine. I dont plan on chaning them out as long as I own the truck. They are good for at least 200k.
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Elder User
Joined: Dec 2004
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From: Springfield, OR
Im 54 years old and we never had any plug problems like this 35 years. For the life of me I wish someone could tell me why they would only cut 3-4 threads into the head to hold a plug in or design it so the plug breaks off. I thought they had spark plugs perfected decades ago but apparently not. Is this just a moneymaking scheme for ford or cheap stupid engineering? If they cant get a head/plug design right how can we trust the rest of the car?
Elder User
Joined: Jun 2006
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From: Fuquay Varina,NC
Its something they probably didnt even think would be a problem. The plug is a whole new design, the threads are in about the middle of the plug, and it extends down, through the head, into the chamber. The problem is, the steel of the plug that slides through the head is a tight fit, and over time gets siezed into the metal of the cylinder head. the most common problem is taking the plug out, it feels normal, and half of the plug, below the threads, is still seated into the head.
Senior User
Joined: Sep 2006
Posts: 392
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If the dealer is charging $1800.00 he is taking the head off to get the broken plug out.
If you read the TSB there are 2 failure modes,one is if the ground shield stays in and the second is the porcelain of the plug stays in with the ground shield.
If the second one happens there is no way to get it out.
If you read the TSB there are 2 failure modes,one is if the ground shield stays in and the second is the porcelain of the plug stays in with the ground shield.
If the second one happens there is no way to get it out.
Elder User
Joined: Jul 2006
Posts: 611
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Hate to say it my next one will have a vortec in it a back yard mechanix can change the plugs in about 30 min. less if you are a real mechanic ford has really got a mess with these heads and they will not do a thing to help, mine is also an 04 and my last.
Posting Guru
Joined: May 2003
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From: Sunny tourist infested FL
Originally Posted by 04 FX4 Lineman
Hate to say it my next one will have a vortec in it a back yard mechanix can change the plugs in about 30 min. less if you are a real mechanic ford has really got a mess with these heads and they will not do a thing to help, mine is also an 04 and my last.
Why wait?