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Broken spark plugs Ford 5.4

Old 04-05-2017, 05:49 PM
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Default Broken spark plugs Ford 5.4

Well the day I have been dreading for 2 years came today. My son has an 08 expedition with the 3 valve 5.4. He bought it against my telling him not to and also told him to make the dealer put new spark plugs in it before he bought it. They refused and he bought it anyway.

I spent 6 hours today changing 4 plugs I was 2 for 4. I changed the front 2 on each side and didn't have the ambition to change the back 2 on each side. What a cluster f@&k whoever designed these damn plugs ought to be taken out back and beat. Seriously what the yell were they thinking ? Obviously they weren't.
Sorry for the rant I feel sorry for you Ford mechanics who have to do this all the time.
Old 04-05-2017, 05:56 PM
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If you deal with them all the time it really isn't a problem. The correct tools go a long way.

That said I still hate those damn things.
Old 04-05-2017, 06:03 PM
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Trust me I had the correct tools. No way would I have been able to get the two broken ones out without. While I do agree if you deal with this everyday you probably become more proficient at it. But it shouldn't be that difficult to change spark plugs.
Old 04-05-2017, 06:06 PM
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At least they didn't blow out. I have towed two 5.4 fords that have blown the spark plugs out of the head.
Old 04-05-2017, 06:12 PM
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Theres a method we use prior to teardown / removal that makes your success rate increase drastically...
Ford has a specific decarbon fluid to use prior to removal & key is to actually get the motor nice & hot & remove plugs then & not wait till engine is cold....
Some things you should leave to the pros....
Old 04-05-2017, 06:47 PM
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Well I'm no shade tree mechanic I've been working on cars since I was 15 and made a good living pulling wrenches for 40 years. I did my homework yes it was hot and kept hot while I was working on it. Funny thing is I remember when I was 16 changing plugs in a Ford about the only way to get them out back then was to have the motor hot.
Old 04-05-2017, 08:22 PM
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When I owned mine my guy removed all 8 in less than an hour. They would hit them with the impact wrench. It would bust the carbon up and they come right out. He was 8 for 8 no issues. might want to give that a whirl.

Good Luck,

TD
Old 04-05-2017, 08:25 PM
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if you have to have "methods" and special tools for spark plug changes then I'm just calling it a bad design & poor quality. some things should be left to the pros like surgery and drywall. Spark plugs????
Old 04-05-2017, 08:53 PM
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3/8 impact takes them out it helps the carbon to break loose when removing the plugs they also sell a tool to remove the broken plugs out I have the tool to remove them Amazon sells the tool.
Old 04-06-2017, 05:23 AM
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I have 4 sets of Ford 3 valve broken spark plug tool removers. I also have a Matco tool that is suppose to get them out without breaking them. It wrenches down on the top of the plugs and tightens up on the electrode and applies pressure to the intire plug. This tool. Broke one plugs porcelain half way up the plug which makes it very difficult to get the rest of it out to get the extraction tool in.
My best friend is a fleet service mechanic for fords only. We talked about the 3/8 impact method but opted not to try it. Honestly if my sons expedition doesn't develop any more misfire issues I will probably not change the rest of them and just in courage him to sell the frickin thing.
We had one several years ago we had to pull the head off of.
Old 04-06-2017, 05:50 AM
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http://www.fordproblems.com/trends/t...rk-plug-stuck/

http://www.aa1car.com/library/ford_tsb_08-7-6.pdf

You should read Ford's bulletin (pdf above). The methods discussed on this thread are not the methods recommended by Ford in the bulletin. Hope this helps.
Old 04-06-2017, 05:54 AM
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Semi retired and not planning on doing any more unless I absolutely have to.
Old 04-06-2017, 03:00 PM
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Originally Posted by oceandansar View Post
I have 4 sets of Ford 3 valve broken spark plug tool removers. I also have a Matco tool that is suppose to get them out without breaking them. It wrenches down on the top of the plugs and tightens up on the electrode and applies pressure to the intire plug. This tool. Broke one plugs porcelain half way up the plug which makes it very difficult to get the rest of it out to get the extraction tool in.
My best friend is a fleet service mechanic for fords only. We talked about the 3/8 impact method but opted not to try it. Honestly if my sons expedition doesn't develop any more misfire issues I will probably not change the rest of them and just in courage him to sell the frickin thing.
We had one several years ago we had to pull the head off of.
My buddy is a master 30 year tech for ford he told me about the impact trick I used it on a truck I got 4 out of 8 out with that method the truck had over 100k miles on it so they didn't want to come out easy.
Old 04-06-2017, 05:52 PM
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Originally Posted by suzuki140 View Post
My buddy is a master 30 year tech for ford he told me about the impact trick I used it on a truck I got 4 out of 8 out with that method the truck had over 100k miles on it so they didn't want to come out easy.
Well that's where I'm at 50% lol 2 for 4. Not sure I really want to wrestle with the back plugs anymore. I did read the Ford bulletins and they say hand tools only and stone cold. My opinion is its a crap shoot sometimes you get lucky sometimes you don't.
Some of the techs I watched on video cracked me up when they were wrenching them out they would say your either gonna be happy or sad when the socket comes out. One poor slob broke 7 and said it was gonna be a very long day.
I still say changing spark plugs shouldn't be that hard.
Old 04-06-2017, 06:23 PM
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Originally Posted by oceandansar View Post
Well that's where I'm at 50% lol 2 for 4. Not sure I really want to wrestle with the back plugs anymore. I did read the Ford bulletins and they say hand tools only and stone cold. My opinion is its a crap shoot sometimes you get lucky sometimes you don't.
Some of the techs I watched on video cracked me up when they were wrenching them out they would say your either gonna be happy or sad when the socket comes out. One poor slob broke 7 and said it was gonna be a very long day.
I still say changing spark plugs shouldn't be that hard.
When you gotta make money you have to find the fastest way and easiest way the impact trick works you can also pour a half can of sea foam in the fuel tank then drive it some that's suppose to loosen the carbon up.Sometimes the bulletins aren't the fastest way I read the bulletin and did the opposite the thing with the impact is you need one that spins fast to help loosen the carbon.

On another note when the 3v motor spits a spark plug out the threads get pulled out of the head to they make a tool to fix that just had to repair my service van it's got the 5.4 2v motor in it the spark plug shot out and pulled the threads out of the head I bought a bad ass kit to fix it worked like a charm took me 30 mins to fix it.The kit was $230 it comes with a air hose plug that you put into the spark plug hole and his hook shop air to it then you turn the motor over by hand the valves close and the air hose plug blows out letting you know the valves are closed.Then you can take the special drill bit and and guide the drill the head out there is a pin on it that stops on the guide then after its drilled out you blow the shavings out with shop air.I use grease in the drill bit and tap then after you drill it you you put the guide back in then run the tap into the hole and once the hole is tapped you can install the special insert they are heavy duty not cheap heli coils you use red Loctite to secure the insert the time cert screws onto the spark plug then you screw into head.

This is the 2v kit I bought
https://www.amazon.com/CalVan-Tools-...lug+repair+kit

This is the 3v kit same thing other than the spark plug size is different
https://www.amazon.com/ATD-Tools-541...lug+repair+kit
Old 04-06-2017, 06:49 PM
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We had one spit the plug out probably 5 years ago put a helicoil in if I remember correctly. I did dump a can of sea foam in on about 8 gallons of gas and drove it before I started. Son says it's never run better so probably not gonna mess with the rest of them unless it develops a miss.
I do have a 3/8 impact that spins crazy fast I may try it next if I have to. Like I said my buddy has 25+ years of experience with f-150 and e-250's and a few others thrown in the mix and we talked about using the impact I just didn't have the nads to try it lol.
Old 04-06-2017, 06:54 PM
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Originally Posted by oceandansar View Post
We had one spit the plug out probably 5 years ago put a helicoil in if I remember correctly. I did dump a can of sea foam in on about 8 gallons of gas and drove it before I started. Son says it's never run better so probably not gonna mess with the rest of them unless it develops a miss.
I do have a 3/8 impact that spins crazy fast I may try it next if I have to. Like I said my buddy has 25+ years of experience with f-150 and e-250's and a few others thrown in the mix and we talked about using the impact I just didn't have the nads to try it lol.
Lol I've done several 5.4 3v engines and used a impact never had a issue what so ever I started using a ratchet I said F*** this and got out my snap on 3/8 impact lol.
Old 04-06-2017, 07:28 PM
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On a positive note, now that the plugs are done..... The 5.4 triton in my experience is pretty damn reliable, and thirsty.
Old 04-06-2017, 07:47 PM
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100,000 miles it was not that bad and I had green heads biting me the whole time I did it, those bastards know when you can't defend yourself.

$100 in plugs and $100 tool was a bit much though.
Old 04-07-2017, 03:18 AM
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I'm dreading it myself, we have an '08 Expedition that just hit 120k miles...and I have been putting off the plug change for 20k miles. I have the extraction tool and a 3/8" impact, just haven't gotten brave enough to try it yet.

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