I've learned a ton and found all the information around changing plugs very helpful, but at this point I think I'm over my head. Hopefully this will provide some valuable information to anyone who runs across similar circumstances.

I have an 03 5.4 with the 2 Valve heads (w/rdesigned plug threads) and 78K miles. I started to feel a miss when it was cold and it finally threw a single #4 misfire code. I replaced the COP and noticed that the plug well was very rusty (a known water issue I learned on FTE), so I ordered a set of boots, springs and plugs and decided to take on the dreaded plug change.

I left #4 for last as I knew it would be the toughest. All the other plugs went very well when I followed all the advice from those on this site. Once I made it to #4, I blew out the well with air and there was a bunch of rusty dust. I added more penatrating oil and gave it an extra 30 minutes, and with virtually no effort at all came out with half a spark plug. The plug was basically rusted in half with the porcelin being the only integral part of the plug. Now I have a broken plug flush with the base of the well with the porcelin still in the head. There is nothing to grab and I'm not sure about busting the porcelin out for fear of dropping pieces into the cylinder. I even started the engine to see if the center porcelin portion would be blown out of the plug base, but it held tough.

I think it may be time to punt to the dealership, as I have learned over the years when to stop digging. The moral of the story is to take a good look at #4 occasionaly and once this is fixed, I'll replace that plug more frequently if I see any rust. I wont comment on my feelings regarding plug or head design.....

Steve

 

There is a removal tool for broken plugs. Not sure if it is Ford specific (they definately have it). Maybe a local auto parts store would carry it or something similar?

 

Just got the bad news from the dealership, $2,700 to pull the head, remove the plug and replace the head. They had no special method for removing the broken portion of the plug.

And on top of that, a week to get it back due to the holiday........

 

Surely you jest!
Go ask an independent shop that same question and I'm willing to bet you can drop at least the "2" off the front of that number.

 

Here's a link to that broken plug removal tool, in case you want to give it a try yourself:

LISLE 65600 5.4L Broken Plug Remover

Good luck!

John