2004 - 2006 Spark Plug Issue??
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New User
Joined: Oct 2004
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From: Castle Rock, CO
2004 - 2006 Spark Plug Issue??
I've come across some posts on this forum that make reference to a "spark plug issue" on the 2004-2006 F-150's. I've not been able to find a post that actually describes what this means. I'm in the market for an F-150 in this year range and would like to learn more about this before I make a buying decision.
MMNC (SS)(Ret)
Joined: Mar 2004
Posts: 11,602
Likes: 148
From: SE Georgia
the heads on the 5.4 3v and the 4.6 3v have an extremely tight clearance around the spark plug electrode.
unburnt fuel/carbon collects in this tiny crevice and effectively can cement the electrode into the head.
The spark plugs are of a 2-piece design.
So you go to remove the spark plugs, and some break apart leaving the electrode in place.
There are several Technical Service Bullitins (TSB) out to correct this issue, but it wasn't 100% fixed until later in 2008 when a whole new head/plug style was used.
If you buy a 04-08 5.4 3v truck...especially from a Dealership, make them do a spark plug change prior to taking delivery. It will be worth the extra $300-500 they might charge you. That way, if the plugs break, it won't be on your dime...I've seen that cost some members here upwards and over $4,000 to repair
unburnt fuel/carbon collects in this tiny crevice and effectively can cement the electrode into the head.
The spark plugs are of a 2-piece design.
So you go to remove the spark plugs, and some break apart leaving the electrode in place.
There are several Technical Service Bullitins (TSB) out to correct this issue, but it wasn't 100% fixed until later in 2008 when a whole new head/plug style was used.
If you buy a 04-08 5.4 3v truck...especially from a Dealership, make them do a spark plug change prior to taking delivery. It will be worth the extra $300-500 they might charge you. That way, if the plugs break, it won't be on your dime...I've seen that cost some members here upwards and over $4,000 to repair
Thread Starter
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New User
Joined: Oct 2004
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From: Castle Rock, CO
Thanks for the info! Is there anything that can be done in terms of regular maintenance to keep this problem from developing? I'm thinking along the lines of removing the spark plugs on regular intervals and cleaning any carbon build-up out of them.
MMNC (SS)(Ret)
Joined: Mar 2004
Posts: 11,602
Likes: 148
From: SE Georgia
that can help...or it can cause the breakage to occur.
lots of guys do a 15,000-20,000 mile pull just for piece of mind.
and you can buy 1-piece plugs now to replace the 2-piece plugs.
depends on how lazy you are really. I personally am pretty lazy. I hate doing sparkplugs
lots of guys do a 15,000-20,000 mile pull just for piece of mind.
and you can buy 1-piece plugs now to replace the 2-piece plugs.
depends on how lazy you are really. I personally am pretty lazy. I hate doing sparkplugs
Elder User
Joined: Jul 2007
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From: Lawrenceburg, TN
Anyone have a pic of the two piece plug v/s the one piece. I thought about trying to pull one of my plugs out to see if they had been changed and to see how much carbon is on them. I bought this truck used and have no idea if/when they have ever been changed. 90000 miles.
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Posting Guru
Joined: Aug 2007
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From: Canton, IL
I wouldn't pull any plugs until you have the lisle removal tool within arms reach. If it breaks, you in a world of hurt until you can get that other half of the plug out. ( a dealership willl welcome you and your wallet though.)
Just my $.02
Just my $.02
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Elder User
Joined: Jul 2007
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From: Lawrenceburg, TN
Yeah thats the only thing stopping me. Its that "what if". I'd hate to spend +/-100$ for that tool only to find that the plugs were recently changed and replaced with the one piece ones though. I may wait till I have a free saturday and give it a chance. I have a backup vehicle in case something goes wrong.
Posting Guru
Joined: Aug 2007
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From: Canton, IL
Ya, but it may cost $400 to $1000 if that something happens and you have to take it to the dealer or a shop. $100 for the tool is cheap insurance. ( i think it can be had for $75).
Let me know how it goes. I've got 107K on mine, and I know mine are originals.
Let me know how it goes. I've got 107K on mine, and I know mine are originals.
Senior User
Joined: Apr 2009
Posts: 168
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From: Houston
Yeah thats the only thing stopping me. Its that "what if". I'd hate to spend +/-100$ for that tool only to find that the plugs were recently changed and replaced with the one piece ones though. I may wait till I have a free saturday and give it a chance. I have a backup vehicle in case something goes wrong.
Look at it as insurance in case shat happens. 
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New User
Joined: Oct 2004
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From: Castle Rock, CO
So do the one-piece plugs fix this problem, or do they eventually fill up with carbon and get locked in place too?
I'm a life long Ford fan, but you gotta admit it's pretty ridiculous that after all these decades of building cars they end up with a problem like this! Oh well, it's still a far superior truck to anything else out there.
I'm a life long Ford fan, but you gotta admit it's pretty ridiculous that after all these decades of building cars they end up with a problem like this! Oh well, it's still a far superior truck to anything else out there.
Postmaster
Joined: Jul 2008
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I wouldn't attempt to pull any plugs on the 3-valve engines without the tool. I've never sold a tool that I've bought for a special purpose. You never know when you'll need it again. I bought a Chrysler upper ball joint socket in the 70's to replace ball joints on a Mopar I had back then. I've been driving Fords since 75 and hadn't used that socket since then until last month when a friend of mine needed help putting ball joints in a Mopar he is restoring. Same with the 6.0L oil and fuel filter socket. I'll keep it. It doesn't take much space in the tool box. I may need to use it again someday. A good quality tool is always a good investment even if you only use it occassionally. They don't go stale and can be kept indefinately. And when you need it, it's there.
Elder User
Joined: Jul 2007
Posts: 893
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From: Lawrenceburg, TN
I agree with you guys. It would be great to have the tool on hand. In my situation I can attempt to pull the plugs, and if something goes wrong, I can just drive my other truck untill I obtain the tool to finish the job.