05 Expedition 5.4, 92K miles. No error codes but been running rough and missing at speed under load, also noticed corrosion build up from leaky antifreeze at heater hose on top of left side of motor. Ordered COP's off ebay and was going to change all of them as well as the plugs. Thought I would do one of the more accesible plugs first to get my feet wet prior to jumping into the infamous #3 and 4 plugs. Sprayed penetrating fluid and let sit overnight, plug didn't cooperate and appeared to break the ceramic below the threads and came out with electrode sticking out about an inch below threads. After lining up the electrode in the broken piece I was able to get broken plug back in the hole and proceeded to changed that COP and then changed all four COP's on passenger side but not plugs. Was able to drive into work but running very rough (imagine that).
Question? What's the best next step at this point? Should I take it into dealership and have them put it on computer to see what's the story or since the plug broke off below the threads should I try and punch it down into the engine and hope I can fish it out by dropping the oil pan. I was planning on replacing the other three COP's on the driver side today just in case one of them was causing the original problem.

Thanks

D

 

You have to (or someone has to) change the broken plug, there's no getting around that.

 

Any suggestions how to get it out?

 

Big Smoke, I went through a similar issue on our '05 Expedition. Here is a link to my post:


https://www.ford-trucks.com/forums/8...nightmare.html

There is a tool listed in the link that can be used for removing the plugs. In my case, I took it to the dealer, and they had to pull the body off the chasis to remove the plugs, breaking 7 of 8 plugs, and the truck only had about 70,000 miles on it. It cost me over $1500 for the change. In addition, either the penetrating oil, or driving for a brief period with a broken plug destroyed my catalytic converter which was another $700 for the converter and two O2 sensors.

This issue is pretty well known, as it happens on the F150's with the 5.4L 3 valve also. Any good mechanic should be able to handle it and can save you money compared to the dealer. Just make sure they use a high temp antiseize on the shield and threads to prevent the issue from happening again.

 

Since just the porcelain broke, why can't you turn it out with a socket?

 

I changed (and broke) the plugs on my 2006 Expy and 2006 F150. Here's my post with pictures and advice. Best of luck to you

https://www.ford-trucks.com/forums/9...ml#post8219650

 

Alloro, It broke the ceramic, but below the threads so there was nothing left to grab ahold of. I was ready to order one of the Lisle removal tools and I thought I would call the dealership just in case they could help without turning it into a full body off restoration . Surprisingly they were able to get it out with a tool they made and only charged me $90 since it was drivers side front and said that if it was in the back that it would have been $250.
Here's some cool info I got while I was at the dealership:
1) They use a product by BG that they use to clean the injectors, throttle body and use it as a fogger through the intake that attacks the carbon buildup on the sparkplug electrode housing below the threads where standard penetrating fluid may or may not get to. I got the impression they have mastered this procedure and pull the plugs immediately after the fogging while the plugs are still wet.
2) The mechanic also stated that he gets the best results when the motor is warm not cold like others have mentioned.
3) He pointed out to me that the COP's that I acquired recently on ebay were for a older model 2 valve 5.4 instead of the 04-05 3 valve that I have and the length was a little longer on the ebay ones which could cause excessive bending. I'm guessing they are probably the same just a little longer boot and spring.
4) Mechanic uses a cordless impact drill to get the plugs out, he says it provides just enough but not too much torque to get them moving.

I didn't have the heart to pay $140 for the cleaning and $190 for the plug job plus parts so I'll be tackling the rest of my plugs tomorrow.