I have read and read about the spark plugs in the 5.4 breaking off into the block. What are the recommended spark plug change out intervals to prevent this from happening in the future? I called Ford on this and they are telling me the change intervals are between 75000-100000 miles. That just appears to be too long if these engines are having such an issue with the plugs breaking off.

 

Good luck. I've researched to crap out of this issue. It's a toss up. I plan to wait until 100k as recommended by Ford, have the Ford Service Department change them. If they break them, they fix at their expense. Otherwise I'm getting a lawyer to fight it. I don't plan to sign any waver from the Service Department either saying if they break it, it's my wallet that suffers. If they can't properly service my vehicle with routine maintenance without breaking it, then Ford is headed down the tubes.

 

I have been searching on the intervals myself. I imagine if Ford says 100000, who would know best but them. However, if the plug were to break when they change them out well they are liable for doing what ever it takes to fix it. After all it sounds like they recommend plug replacement at 100000 miles.

 

100k miles seems awfully long to wait between plug changes? i would think it would be best to change em before they become to seated and seized into the head. toss on some anti-sieze as well.

i havent really researched but i have heard about the issue and it concerns me, but regardless of the plug breaking, 100k just sounds like a long time to go w/o changing them.

 

Sorry.... That was supposed to be dead horse... No smile for that one...

 

Have them changed out before 80,000 miles, I highly recommend at a dealership because if they break off in the head(pssst... don't tell anyone I told you this) Ford can and will cover the repair of removing the plugs under their 8yr/80,0000 mile emissions warranty!!!!

 

Thanks for the replies. I will for a fact have the dealership do the job. I know if I did the simple job of spark plug replacement at home and it broke off inside. I would be screwed and highly pissed. I will leave it up to the dealership.

 

100K is not that long for plugs in modern vehicles. My Escape has 99,000, my Town Car has 110,000, my cousin's 05 F-150 has 168,000 and all run fine on their original plugs. My friend finally had a misfire with his Taurus at 160,000 miles but it was a plug wire (but he did change the plugs). If you get a misfire, the check engine light will come on.

 

I've been searching high and low since 15k miles on what to do about this situation. I've got 37k now and didn't buy any extended warranty. I challenge anyone to research this as much as I did. I called at least 20 dealerships in Georgia and South Carolina. I've talked to independent shops. I've heard from many that they've never heard of a problem(yeah right....). I've had others say yes they have heard but never had a problem at theirs. Some said they have had 1 or 2 but the plugs were able to be removed without removing the heads(talking to them sounded like I was asking an alcoholic how much he drinks: only 1 or 2, chuckling under their voice). Still others said they have had to do major work to get the plugs changed, including removing the heads. After finding out that the stats were all over the place, the other problem was how the financial part was handled. For the sake of this post I won't begin to go there. My conclusion: It's a darn toss-up. One thing for sure, I don't plan to attempt it myself. I want Ford, who made the darn thing, to take a "crack" at it, sorta speak(no pun intended). That way, I'm the one pointing the finger. Besides this, I love my truck. 37k trouble free miles and I mean NO PROBLEMS. Can't say that about my 03 Z71 POS. Best trade I ever made.....

 

I have not had any problems with my truck (Knock on wood ) so far. I beleive the dealerships have a tool so they can remove broken plugs without disassembly of the motor.

 

I just had this done...at 56k because of threads like this.

I got the bill from the dealer. I paid the bill from the dealer (because I like the people and trust the service dept.-It's not their fault Ford had a bad design, why get mad at them?)

I had the ESP extra care program...yesterday I sent out lots of letters with copys of the bill (Over 500dollars in labor to get the plug out-#7 plug to be exact)

The tool only works in special situations... mine wasn't so special




Anyone had any luck getting the moola out of Ford(after the fact), or did I screw the pooch by paying my service dept?

 

The factory recommended interval is 100K miles, and probably the reason for not hearing much about this is because the 5.4 3V is only 3 to 4 years old. Not many have hit the 100K mark yet. Stay tuned!

OBX - I wonder if the tech followed the TSB to a T as in performing a soak before actually removing?

 

I wouldnt have paid the $500 price tag. Especially if the spark plug change out is 100000 miles. Ford should have issued a service bulletin on the Spark Plug Issue (Or did they? ).

 

Ford has issued a technical service bulletin. It is listed on this websites TSB tab.
I replaced mine at 41k miles. I did it myself and had no issues. I did follow the TSB....basically with the engine warm. Not hot nor cold soaked. Loosen the plugs 1/8th turn spray penetrating oil...let the oil soak ~1/2 hour or more (TSB says 10 minutes). Then slowly loosen the plug. It creaked and groaned but all came out without breaking. The issue is carbon build up around the extra long electrode.
I did mine at 41,000 miles to minimize the chance the plugs might be that much harder to remove at 100,000miles? Time will tell as the 04's and 05's mileage average gets closer to 100,000 and people start changing them. I'm hoping its not as big an issue as people make it sound. My plugs did not look warn out at all at 41k....just some mild carbon build up around the extended electrode.
PS: You'll need a special size (9/16") spark plug socket if you do this yourself.....

 

I have an 04 with 105,000 miles with the original plugs. I found out about this problem after 60,000 miles. I have no problems still, but waiting for the dreaded day to replace them. I understand it is a carbon build-up problem. I know GM has had problems with the 4.8, 5.3, 6.0, and 8.1 engines with carbon build-up which made the engine knock of some sort. anyhow, their fix for it was some kind of carbon cleaner that was injected through the fuel rail. I am thinking that I may do the same process with my truck prior to changing the plugs. It's worth a shot. I have heard through the grapevine, the Hemi's have problems with plug removal as well.