04-06 Plug Warning
Freshman User
Joined: Mar 2005
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Just got off the phone with my local dealer and this is what I was told. TSB 06-5-9 can only be performed if the customer reports a problem. This TSB is more of a "how to" guide than anything. There is a NEW TSB that supercedes TSB 06-5-9 and that number is TSB 06-15-02. This TSB is covered under the emissions warranty which is good for 50K miles. He suggested to me to come in at 49K miles for a tune up this way if something does go wrong, it will be covered under the emissions warranty. I know how some dealers can be, but the dealer I have worked with for my trucks (84, 92, 99, 04) has always been fare and a straight shooter. He printed off the new TSB and an Oasis report for my truck so I can pick it up tonight. Just thought I would post the findings for future reference.
Laughing Gas
Joined: Jan 2005
Posts: 1,055
Likes: 3
From: Magnolia, TX
Just for reference, here is a thread I started recently that details all the "how to's" when replacing the plugs yourself: LINK HERE
CMOS
Edited to add: Yes, I'm not happy at all that Ford KNOWS about this and isn't taking care of the customer.
CMOS
Edited to add: Yes, I'm not happy at all that Ford KNOWS about this and isn't taking care of the customer.
Posting Guru
Joined: Jul 2004
Posts: 1,479
Likes: 4
50K mile tuneup? Ford specifies 100K so something is a miss here. I think the 50K is the dealers schedule not Fords.
Just pulled the 06-15-02 nothing references a 50K change or emissions tune up! I think your dealer has his own schedule, it's not a Ford schedule! What in the world is an emissions tuneup? You have the list of what they do? These so called dealer schedules is just a way to make more money, when it really is not required, or it would be part of the manufacturers schedule. BTW the earlier TSB also states covered under the emissions warranty( see below). The only difference after reading the two is that newer 06-15-2 adds the PN for the antiseize compound.
Think your dealer is a little confused!
Just pulled the 06-15-02 nothing references a 50K change or emissions tune up! I think your dealer has his own schedule, it's not a Ford schedule! What in the world is an emissions tuneup? You have the list of what they do? These so called dealer schedules is just a way to make more money, when it really is not required, or it would be part of the manufacturers schedule. BTW the earlier TSB also states covered under the emissions warranty( see below). The only difference after reading the two is that newer 06-15-2 adds the PN for the antiseize compound.
Think your dealer is a little confused!
Last edited by KevinM; Jan 11, 2007 at 01:54 PM.
Senior User
Joined: Nov 2006
Posts: 351
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From: buckley WA
I am betting if you use a top tier gasoline for the life of the vehicle you won't have the plug problem. I bet cheap gas is causing carbon deposits and making the plugs difficult to remove. Time will tell.
Freshman User
Joined: Dec 2006
Posts: 25
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From: Keedysville, MD
Wow, I just got a new 06 today and Im reading this, grrrrrrr. I just traded in an 04 with 41000 on it to the dealer, At what mileage should i change the plugs 25k ??? and is anti seize the solution ??? Plugs and anti seize every 25k ???? Both the 04 and the 06 have the 5.4 engine and I love it, Please tell me my heart is not broken...
Steve.
Steve.
New User
Joined: Nov 2006
Posts: 17
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Crap i thought it was the threads binding in the head. Gonna pull them out again this weekend and coat the insulator sleeve too. Those scmucks machined the head too narrow at the sleeve point. There is no reason they coulndnt have put a slight taper that narrowed towards the tip of the plug. Stupid engineers re-inventing the wheel. Way to go!
Todd
Todd
Last edited by Beast12; Jan 12, 2007 at 05:58 AM. Reason: removed masked profanity
Fleet Mechanic
Joined: Nov 2000
Posts: 1,713
Likes: 2
From: In my House
I'm no engineer, but the way I see it, is once the antiseize is put on, then we shouldn't have a problem, as, there isn't going to be a place for the carbon to build up on the plug, except for the tip. I just can't believe that there could be that much carbon buildup on the plug to not allow it to come back out 
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Brett Foote
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Joined: Jan 2007
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Originally Posted by 96f150
I really wonder if a plug re-design is in the works. Any 2007 takers on pulling a plug from there engine to look?
I've always been a GM Truck guy, but I am considering buying a Ford since this version has been out since '04, I was thinking that it would be rock solid. The GM Truck is a brand new version so in theory I would have less problems with an established Ford.
I might be rethinking that theory unless someone can point me to something that says this problem is truely fixed on the '07s. I know it's the same Triton 5.4, but are they now at least adding the anti-seize lubricant solution to the '07s ?
Laughing Gas
Joined: Jan 2005
Posts: 1,055
Likes: 3
From: Magnolia, TX
Originally Posted by F150 Dude
Wow, I just got a new 06 today and Im reading this, grrrrrrr. I just traded in an 04 with 41000 on it to the dealer, At what mileage should i change the plugs 25k ??? and is anti seize the solution ??? Plugs and anti seize every 25k ???? Both the 04 and the 06 have the 5.4 engine and I love it, Please tell me my heart is not broken...
Steve.
Steve.
F150Dude,
Yes if you pull the plugs about every 25-30K after you've coated the threads and ground sleeve extension with nickel based anti-sieze you should have no problems. Remember, you have to toss the plugs if they look reasonable. Just clean them, apply anti-sieze and re-install.
Pain in the *** I know but if that's the only issue with the 5.4 3V I'll still be happy with it.
BTW, I just got all the tools, etc. I need so I will be changing my plugs this weekend.
CMOS
Posting Guru
Joined: Jul 2004
Posts: 1,479
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Chris1450 - I'm beting it's more than the carbon buildup but the electrolysis effect of the long ereach plug against the aluminum head. Two disimilar metals cause corrosion and in effect weld themselves together. Hence the reason for antseize as called for by the TSB.
Carbon is a by product in all no lead gasolines today. The reason higher levels of oxygenates! Oxygenates have a minimul concentration level as set by gov't standards and law. So even the low end fuel that skimp on additives will still produce carbon. Go look at your tailipie!
Carbon is a by product in all no lead gasolines today. The reason higher levels of oxygenates! Oxygenates have a minimul concentration level as set by gov't standards and law. So even the low end fuel that skimp on additives will still produce carbon. Go look at your tailipie!
Freshman User
Joined: May 2004
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Guys, if you could see the plugs when they have been removed you would get an entirely different take on the problem. It is not the threads...rather it is the shield. I've been trying to post a link to something that appeared a year ago on this site that shows the photo but I get some type of an administrator block flashing momentarily across the screen. Google '5.4 spark plug problem' and you should find the post.
Laughing Gas
Joined: Jan 2005
Posts: 1,055
Likes: 3
From: Magnolia, TX
Originally Posted by 96f150
CMOS, you mean "don't" toss them if they look reasonable...right? Please keep us posted on how you make out.
Correct. If you've only got 20-25K, might as well re-use the plugs if they look good. On the other hand, if you can easliy afford to replace the plugs I would personally opt to do that after spending 3 hours pulling them.
CMOS
Thread Starter
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Senior User
Joined: May 2004
Posts: 191
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From: San Diego, CA
You are taking an extra risk re-using the plugs. Part of the problem is also the way the plugs are made. The shield is not welded to the nut piece. If the shield has partially corroded to the head and is difficult to remove then the press fitting between the shield and nut may have started turning a little (screeching noise) when you removed the plug. When the shield is stuck tight and you continue to wrench out the plug the press fitting will allow the nut to turn and strip out the aluminum threads. The result is affectionally known as a "spinner". Some of course break off. Every time you remove these plugs and there is resistance from the corrosion you are weakening the threads in the head and the press fitting holding the plug together. It would be smarter IMHO to put in new plugs and maybe there is an improved welded plug. This defect is even worse than the "blown plug defect" because there is no way to really fix it. All you can do is pull and clean the plugs every 10-15000mi before any carbon or corrosion starts. At least the blown plug could be permanently fixed with the TimeCert. This is a disaster for the 04-06 5.4 3V guys.
Last edited by Fasterhorses; Jan 12, 2007 at 10:05 AM.