Posted to Technical Tips Forum on 11/25/2009
04 Ford F-150 5.4 Spark Plug Removal
Most iATN members are aware of the Ford 4.6, 5.4 and 6.0
spark plug breaking issue. Having the same frustration, even
when following the Ford service bulletin I have added some
steps that seem to help aid in the removal of the plugs
The Ford service bulletin 08-7-6 which updates 08-1-9 is of
some value, as I follow those steps after doing some prep
This is what I do.
1: Explain to Owner that this is a long process and they
will need to be without their vehicle for two maybe three
days. I try to convince owners not to exceed 80,000 miles
for spark plug replacement interval.
2: The first morning run engine to operating temperature and
remove the crankcase vent hose, the small one on the
passenger side of the air cleaner housing.
3: Either use a pedal jack or have helper hold throttle to
2,000 rpm. Using suction spray nozzle, spray GM upper engine
and fuel injector cleaner #88861802, into the vent port on
air cleaner housing. After 3 ounces have been used and while
still spraying have helper shut engine off. (throttle still
4: After sitting for 1 hour repeat step #3 after running
engine to operating temperature.
5: Before closing on day 1, Repeat step #3 again after
running engine to operating temperature. Place vehicle in
the bay in which you intend to work. This allows engine to
cool overnight to ambient temperature as necessary.
6: Day 2 start plug removal process.
I also add the following steps to the next phase of plug
1: Break the plugs 1/8 turn only, then fill to hex of pug
with penetrating oil. I use PB blaster. After 1/2 hour
tighten plug and loosen 1/4 to 1/2 turn be sure penetrating
oil is still to the hex of the plug. After 1 hour, tighten
plugs and then work them out alternating loosening and
I have found that while removing the plugs if they squeak,
they come out intact. No squeak and they are broken.
Using these additional steps I have been able to remove
plugs with no more that 2 breaking. Some 1 and others none.
I may be doing more work than necessary but it is a pain to
remove the broken tips.
Speaking of removing broken tips, the tool that I have found
to work the best is the Lisle #65600.
I listed this as 04 F150 because this is the vehicle that I
just finished. #6 broke, all others came out intact. This
applies to other Ford vehicles.
Hope this helps make it easier for some Members.
Thomas from South Carolina
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