04 Ford F-150 5.4 Spark Plug Removal
Posted to Technical Tips Forum on 11/25/2009
58 Replies
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
without breaking.
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
work.
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
held open)
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
removal.
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
tightening.
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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