The TSB covers 04-05 F150, 05 Super duty, Expedition, Navigator with 5.4L 3V engines.
The procedure is: warm the engine up till it's warm to the touch, remove the COP's, blow out the hole and surounding valve cover area to remove dirt, break the plugs loose 1/8th of a turn, spray penetrating oil (prefirably Kroil brand) to fill the well to the top of the jamb nut of the spark plug, let sit for 5-10 minutes (my experiance is longer is better) Then turn the spark plug out.
If you do break a spark plug off and just the ground shield is left the Ford tool for this is 100% in removing it.

What does the ford mystery tool look like ?

Jim3,

Go HERE to see the whole TSB that also shows the tool.

CMOS

I was also hoping to avoid problems down the road so I just finished re-installing my plugs today on my 2005 SC with 25k miles. Longer is better with the soak time of the penetrating oil, I waited a min of 30 mins (didn't break any plugs), applied a film of nickel anti-sieze, and torqued to 25 ft-lbs. I plan to remove again at 50k miles and I'll see if the anti-sieze makes a difference. This is a job requiring patience...

Jeff: How bad did your plugs look as to the carbon build up issue, that is usually the reason they won't comeout???

Jeff,

Did you move the PCM case to do the 2 rear plugs on the passenger side?

I talked to a couple guys that moved the PCM, not disconnect - just moved aside, and they said those 2 plugs were an easy straight shot.

CMOS

The plugs didn't look too bad. But it looks like it doesn't take much to bind them...it's a tight fit, that's why I'll be looking at them again in about 25k more miles. I didn't think of it but I should have taken a picture.

I did remove the box and it's mounting bracket to get the 2 rear plugs on the passenger side...with it out of the way the passenger side is easy.

I can't believe Ford has another issue with spark plugs...I read that MY2006 and MY2007 have anti-sieze applied at the factory to solve this issue, anyone know if this is true?

Do you mean anti-sieze on the threads or the extension sleeve?

CMOS

I would think on the extension sleeve...

Question: How many of you actually used a torque wrench when you replaced the plugs versus just tightening then by feel?


CMOS

My dealer quoted me $320 for plug change , why such a difference?

Probably because $450 = city of Houston. :-X15


CMOS

I can't think putting anti seize on the plug extension will do any good at all as it is in the combustion chamber and will burn off very fast and beleive I read somewhere ford does not recommend using anti seize this way anyone out there know????

They sure do - Ford suggests doing so on the Spark Plug TSB here. See the "NOTE" towards the bottom.

CMOS

This is kinda confusing. So they DON'T want any "Anti-Sieze" (Lubricant) on the threads ??? Thanks for finding this TSB for us !!!

~Glenn