Spark Plug Issue
Postmaster
Joined: Jul 2008
Posts: 2,565
Likes: 2
The redesign did indeed apply to engines from 7 Oct. of 2007 and onward. That would also include early 2008 engines as well. That would make all 2004 thru 2007 5.4L 3 valve engines susceptable to the problem of breaking upon removal as well as early 08's. From what I've been told all 3 valve engines are affected. I wish that I could find a standard resistor plug in the proper heat range for my 06 5.4L That's what I would go with. Detonation and platinum plugs are lethal to an engine. And if you tow close to the max of your tow rating you are flirting with the possibilty of ruining an engine as it gets some miles on it. All it takes is a hiccup from the fuel pump.
Senior User
Joined: Feb 2006
Posts: 257
Likes: 0
From: Kingsland, GA
Realize that the plug issue should only be applicable for replacement of the original plugs. By procedure, the shield of the new plug(s) is coated with high temp anti-seize prior to installation, which should significantly reduce the chance of breakage on the subsequent replacement...
Posting Guru
Joined: May 2001
Posts: 1,082
Likes: 0
I replaced my plugs at 112k and broke 4 of them. Had the Lisle tool on hand and it worked beautifully. Used Motorcraft plugs. Since I have the tool, I didn't use a higher priced plug just to avoid the issue. I probably won't keep the truck long enough for a second plug change anyway.
Elder User
Joined: Feb 2008
Posts: 783
Likes: 1
From: Chicago Area, Illinois
Im actually about to turn 100,000 miles on my 04 and just called literally minutes ago to the dealership. I have 4.6 2V in mine and i was quoted $148 parts and labor. he understood that mine was the 4.6 2V without the problem. So when i drop it off im going to get that in writing.
No need to worry. The 4.6 2V motor does not have the plug problem. Different head, different plugs on the 4.6 I changed mine at 90,000 and had absolutely no problems at all getting the old ones out. I did put anti sieze on the threads and torqued them to the spec that was listed in the service manual. I replaced them with the OE motorcraft plugs. Actually the plugs that came out of my motor looked like they had 30,000 miles on them instead of 90k. I was plesantly suprised how clean the old ones were.
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Junior User
Joined: Nov 2009
Posts: 68
Likes: 0
From: socal
About to do the second plug change on my 05 with 120k. Did first change at 90k with no broken plugs. However I removed cops and penetrating lube soaked over nigh, only cause when I attempted to remove them, they seemed way to tight. So common sense, lube it up. So i will be changing at about every 30k or so as I plan on keeping the truck forever.
Junior User
Joined: Nov 2010
Posts: 71
Likes: 0
Changed mine at 101,000 miles, pretty much a month after I bought her. The plugs were so burned up the gap was like 3/16 of an inch! It was a miracle the truck even ran. So with the new plugs put in and properly gapped it ran like a brand new truck again! I hope to not see those plugs for another 8-10 years or 100,000 more miles, whichever comes first 
Junior User
Joined: Jun 2007
Posts: 56
Likes: 0
From: Kansas
Homemade spark plug extractor tool...
Just saw this thread at a Mustang forum...
Spark plug horror?... Enter Snap-on spark plug extractor - Ford Mustang Forums
Cost about 5 bucks to make.
Spark plug horror?... Enter Snap-on spark plug extractor - Ford Mustang Forums
Cost about 5 bucks to make.
Cross-Country
Joined: Dec 2005
Posts: 97
Likes: 0
From: Lexington, SC
I pulled my plugs at 67K and they were shot. I did the change early to avoid the broken plug issue, but after seeing the plugs I would go no more than 50K intervals. My gap was out by .100 to .150. I can't belive she was not skipping. After doing much research through the forums I put motorcrafts back in. I love this truck and plan on wrenching on her for many years to come and putting OEM back in just seems to eliminate one more variable when trouble shooting the skip, hesitation, stall, bad MPG, what have you down the road.