mowreyp

I have a 2004 F150, FX4, Extended cab, with the 5.4 engine and 43,000 miles. I've heard that the spark plugs have been seizing in the engine, breaking when being replaced, and causing thousands of dollars to repair damage. I called two dealers for advice and both recommended that I replace the plugs immediately. One wants $250 to do it and the other wants $300. The plugs cost $17 each. One said he had to buy $800 worth of tools specifically for extracting these plugs because they tend to break inside the head. Both service departments responded immediately and seemed to be familiar with the issue.

The original plugs are 100,000 mi. plugs. Unfortunately, a combination of faulty design of the plugs and the head have led to the current problem.

I called Ford's Customer Service and was told that Ford has nothing to assist its customers in dealing with this mess. Ironically, the plug manufacturer (Champion) gets to sell replacements much earlier than they normally would and Ford gets unnecessary service work for its dealers. Those who caused the problem get rewarded at the cost of their customers. So much for customer "service".

Has anyone gotten Ford to take responsibility for this problem? I don't expect them to pay for everything but they should provide assistance.

phantom_smack

Trust me its no fun for us changing them either if you break a back plug there is now way they can be changed in the alotted time.

beaudointl

Although the plug replacement schedule is every 150,000kms or 100,000 miles, they should be pulled and inspected every 50,000kms or 30,000 miles. Clean the threads, apply the proper anti-seize and reinstall. This usually prevents the plugs from seizing in the block. We have done this at our shop for the past few years and have had great success.

tinkersdelight

been there and done that! Get that anti sieze on there asap. I changed mine at 110,000. Broke one off and had to buy a spendy extractor tool. Here's what I discovered that worked.

I used to work around the logging helicopter companies. One of my logger friends sent this to me and it is good stuff. Get AEROKROIL. It is penetrating oil specifically for aluminum. The night before I worked on the remaining 7 plugs(after I got my courage up a month later), I loaded each hole with this Kroil and let it set all night after warming the engine. Then in the morning, blew it out with air. All the other plugs came out without any more breakage. A couple were tough, but they extracted!

Another trick is that you can't get straight leverage. I made a thick steel washer to fit on my extension out at the top of the hole. This way you keep your socket straight and you can apply straight leverage with less danger of breaking a plug.

Steve83

It'll probably take a class-action lawsuit before Ford (or Champion) accepts any financial responsibility, but the short answer is: you bought it - it's your truck. If it's still in-warranty, you're covered. If not, you had the opportunity to buy extended coverage, and you chose to go with the regular warranty. There was no problem during the warranty period, so you got exactly what you paid for - be happy. Suckers who just bought Chrysler products will be crying soon...

BTW
The special tool kit costs ~$80 from Snap-On, and there are plenty of videos on the net showing how to do this. You can even read the full text of the Ford TSB that describes it. Google "TSB061502" or "TSB 06-15-02" or "TSB 06-15-2"...

__________________
Walk softly & carry a BIG SIX ! ! !

. . . '99 CV RIP

ebtdm

Wow, Just went through this and the posts are elsewhere in the forum. I got the extractor tool for about $60 on the net including shipping. Two plugs broke on me, one plug rounded, and one of the new ones fouled out after 150 miles. The original post on this thread was about a year ago and mowreyp had only 43K on his '04 and was talking about having someone else do the work. He is done by now and the bottom line is that plug replacement is a few hundred bucks and does not cover head removal and repair if necessary. Standard warranty does not cover it. A service contract may have a clause to absolve coverage for this issue. For those reading this, do more research, as there are several posts here that offer some good and some advice that may be shortsighted.<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:office:office" /><o:p></o:p>
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Skatervideoguy

HI folks,

Considering getting a new F150 with the 5.4 engine. Does all this mean I should reconsider getting the 5.4, or at least remove the plugs ASAP and put the anti sieze stuff on them ??

Harold

jwko

I think putting anti-seize on asap is a good idea. Also, change the plugs ever 25-30k instead of 100k intervals.

Steve83

Did you read the TSB?

__________________
Walk softly & carry a BIG SIX ! ! !

. . . '99 CV RIP

Skatervideoguy

Hi Steve83 & jwko,

Thanks for the info, I'm trying to find out if this issue also (or still) applies to the newest version of the 5.4 (2009), as that is what I'm looking to buy.

Harold