Important Tip for 5.4 owners

[Blackstock]

We have had instances of the 5.4 spark plugs breaking when being removed. Ford provides us with a special tool to remove them, however if the rear plugs break it requires removing the head or the if both break remove the engine. Scheduled maintenance suggests inspection or replacement at 100,000 or 160,000 kms depending on model. I reccommend you have the spark plugs inspected before the warranty expires. Either way it is an owner cost to inspect/replace but should they break warranty covers to remove them, saving a potentially costly bill.

[Viper238]

Thanks for the heads up..
Maybe I'll have this checked out since I'm boarding the 60k.. (58,550km)

Have an idea what spark plug change would cost?

[Lightning Steve]

That's for the info.
Do you have any information on the problem of Lightning 5.4 plugs blowing out of the heads (the 4 thread heads-think 2000 to early 2003), have heard that Ford will now fix for free, even out of warrenty, is this true?

[Blackstock]

I'll have to look into that one for you. Any after warranty adjustement, goodwill whatever you want to call it is now dependent on if the owner can prove maintenance at a Ford dealer. Then the guidlines are are under 100,000 k. I'll check though

[Bush_aholic]

I blew 2 spark plugs rite out of my heads last year when she was at 190000km. I got ford to send the heads out and got all eight holes machined.

[MRGADGET]

It's a 2 1/2 hour job at 90.00 per hour.
about 15.00 per spark plug.
If a Cod is faulty then they are about 145.00 each.
If it's just the spark plugs then about 300.00 to 350.00

[Viper238]

cost me $266 plus tax to get mine done!
They were all decent looking.. so I guess I'm off to the races again.. lol

[Denis254]

what year anyways.. i still got a long way to go to 100.000 im at 16.652 lol

[LaredoRV]

Took me a new engine in my 2004 Lariat... Thanks warrantee :icon_razz:

[SKRWZ]

Hopefully this can save someone some money down the road.

You can pay a little now or allot later

[starsticks078]

Thanks for the info Blackstock!!

[lightning25]

That's for the info.
Do you have any information on the problem of Lightning 5.4 plugs blowing out of the heads (the 4 thread heads-think 2000 to early 2003), have heard that Ford will now fix for free, even out of warrenty, is this true?

Steve, i dount this is true....damn cheap companies making faulty products!
there is a lot of discussion of this on svtperformance.com that i have read in the past.

just be sure to use anti-seize on the threads (to solve breaking the plug) - as for plugs blowing out, the only thing i know to do is to torque them to proper spec (i'll be doing this in a few months to mine).

[Lightning Steve]

If you haven't changed plugs on the L are you in for some fun!!
If you want to get together some time when the weather warms up for plug changing let me know.

[f150phule]

Hey the 6s are no easier to change either :icon_lol:, there just isnt any room and unless you are a contortionist they are a major PITA to get the #3 & 6 out.

[1stf150]

I pulled mine out at 80k just to check and the back two were almost seized in there. If you waited until 160k, their not coming out. Recomend spinning them out every 80k at least and don't forget to use anti-seize on the threads for sure.

[lightning25]

If you haven't changed plugs on the L are you in for some fun!!
If you want to get together some time when the weather warms up for plug changing let me know.

my truck will be in the garage in april for my "mods" i'll be working on and ill have the s/c off so she won't be driveable.
if you wanna come down and change em w/ me, sure (and urs too)...have a few beers and get mad as we try to change them...lol!

[f150phule]

I smell a spring road trip GTG in Sarnia :icon_lol:

[ColinRX7]

Thanks for the tip. I'm at 90,000 on my 06, so I guess I should have the dealer take a looksie?

[tohi2care]

I am at 43k kms and asked the dealer for a quote on how much it would cost to inspect the plugs and this is the info I got......



Operation: RM117 - Sparkplugs r&r 5.4L 2006 from 8-8-05

Notes: (Inclus. plugs inspect ignition sysytem & filters, adjust fuel systemas needed)

Labour hours: 2.00

Qty------Part Number----------Part Descrption------------Part price------------Ext Price
---8------FOSP-462 -------------SPARK PLUG---------------18.50---------------148.00

Misc Code-------------Misc Description-----------Quote Min----Quote Max--------Price
BSS-------------------SHOP SUPPLIES------------------------------------------14.72



Labour $:------184.00
Parts $:------148.00
Misc. $:------14.72
------------------------
Subtotal---$ :-----346.72




Now my dealer said

"We (the dealer) will not be responsible for any damages caused by removal of the plugs after the basic warranty runs out @ 60,000kms."

Is this bullshit or what. I pay extra to buy a supplemental new vehicle warranty to 160,000 kms and then they tell me that it will not cover the plugs braking off in my head after 60,000kms:wtfsign:

[fordtough.ca]

I'm surprise
I'm changing my at 59,998 km just in case

[Irish FX4]

We have had instances of the 5.4 spark plugs breaking when being removed. Ford provides us with a special tool to remove them, however if the rear plugs break it requires removing the head or the if both break remove the engine.

Not true. here is a post on another forum and the guy broke his back plugs and got them out.


Originally Posted by Irish FX4
I heard that if the plugs at the firewall break you cant get in there with the tool to remove the broken piece? Then your looking at either the heads coming off or the motors coming out! Can anybody clear this up for me. by the sounds of the poster he got his out and it was the back plug that broke!

I have almost 60,000km on mine and i am thinking of replacing them in the spring.

Thanks.

His reply!
Mine was drivers side firewall. There is tons of room to work on these trucks. Even back at the firewall. I didn't take the fuel rails off like some guys have. The only thing I pulled off was the computer (I assume it was the computer) on the passenger side firewall. It made that firewall plug much easier to get at. I had no problem getting the tool into the firewall plug. My gut was a little sore from lying on it for an hour or so, but I really took my time. I could have done it in half the time if I wasn't no nervous about breaking the tap off.

[white4by4]

Is there any of these related issues with the 4.6L engines????

Thanx in advance for any info.

[Limited Randy]

Just wondering if ford has done anything to fix the problem.

[lightning25]

fix it by adding extra threads on the head? yes. the 2002 (or 2003 i cant remember) has a few more threads, making this not an issue.

Fixing it on older trucks with the issue? No - ford has not done anything to aid its customer if you are in this situation. all you can do is proper torque and apply never-seize and hope your plugs dont blow!!

[ninjabill]

fix it by adding extra threads on the head? yes. the 2002 (or 2003 i cant remember) has a few more threads, making this not an issue.

Fixing it on older trucks with the issue? No - ford has not done anything to aid its customer if you are in this situation. all you can do is proper torque and apply never-seize and hope your plugs dont blow!!

Does this apply to 08 F-150 as well? Did some dumb ass over torqued the plugs at the assembly line? I just bought an 08 F-150 and hopefully I don't have this problem.

[shelbyx1]

Does this apply to 08 F-150 as well? Did some dumb ass over torqued the plugs at the assembly line? I just bought an 08 F-150 and hopefully I don't have this problem.

Bill:in late 07 they changed the design of the plug for this concern,they had a 2 piece lower portion on the hex thread portion that was bonded,it's now one piece,as far as removing engine or cab all plugs are accessable in vehicle (i've been changeing them since 04 in vehicle):)

[LaredoRV]

We have had instances of the 5.4 spark plugs breaking when being removed. Ford provides us with a special tool to remove them, however if the rear plugs break it requires removing the head or the if both break remove the engine. Scheduled maintenance suggests inspection or replacement at 100,000 or 160,000 kms depending on model. I reccommend you have the spark plugs inspected before the warranty expires. Either way it is an owner cost to inspect/replace but should they break warranty covers to remove them, saving a potentially costly bill.

Happened on my 2004 :icon_cry:.... Received a new engine on the warranty...

[ninjabill]

Bill:in late 07 they changed the design of the plug for this concern,they had a 2 piece lower portion on the hex thread portion that was bonded,it's now one piece,as far as removing engine or cab all plugs are accessable in vehicle (i've been changeing them since 04 in vehicle):)

Thanks for clearing that up for me.:icon_razz:

[Lord Helmut]

I will do that thanks for the info

[urbansherpa]

That's interesting.

I had my plugs done at 52,000km w/i the warranty period and was charged about $500+ dollars. I was told that if I didn't get them done they'd crack and it would cost me up to $3500. to take the head off.
I asked about the warranty and they said NO, IT IS NOT COVERED UNDER WARRANTY. I was worried sick about it, but none broke. Now I find out it IS covered!!! hmmm

I have since had MULTIPLE warranty problems with that dealer over brakes, fuel injectors, and emissions. I vowed NEVER to go back there. The Service Manager is a smug SOB.

Brakes (within warranty period) -parking brake didn't work, went right to the floor. They told me I had to get the brakes torn down every 20,000km or it voids the warranty. I had 45,000km on them at the time. Cost about $200. to unseize the drum brake.

Fuel Injectors -three of them went on me to a total of $700. Said I'd pay the next day. After looking on the internet I found it was covered under a 192,000/11yr warranty.
They were willing to take the $700 from me until I had FordCanada advise them otherwise.

Emissions -I now have been told probably have a blocked Catalytic Convertor that may have been caused by the three Fuel Injectors blowing.
Dealer tells me it isn't possible, another dealer tells me otherwise. *I've got an appointment at the 'other' dealer tomorrow.

Other stuff- taken the truck in for multiple issues that probably should have been covered!!! I've vowed never to set foot in the place again. I had figured that they are a reputable Ford dealer so why would they steer me wrong?.....after several dealings and much Googling I wised up!

PM me if you want the dealer or service managers name.

[RADBMXER]

You should post it publicly on here.. I don't live anywhere near your area, but I have dealt with BS like that before...

[TRUKNUT]

I was at erinwood for service last week so I asked the servce advisor if the spark plug
removal was going to be a problem on the 2009 5.4's . got a bunch of psycho babble
from him (he seemed stund by the ?)so I'm not really sure if it is still a problem or not .

[shelbyx1]

I was at erinwood for service last week so I asked the servce advisor if the spark plug
removal was going to be a problem on the 2009 5.4's . got a bunch of psycho babble
from him (he seemed stund by the ?)so I'm not really sure if it is still a problem or not .

the head and spark plug design was changed in late build 07 5.4l(the sleeve that would seize and brakeoff in head is now threaded)

[gtn]

i have a broken plug in a 5.4 where can i get a removal tool ex: Lisle 65600 dlt

[SToFF]

so is there a way to check which engines build in late 07 are now threaded? like a serial sequence (such and such and up are changed and such and such down are the old way) I am coming close to needed a spark plug change on my 08 and the dealer advised me spark plug warranty runs out at 20000kms. So needless to say I am a little worried about how much this fun is going to cost me.

thank you

[shelbyx1]

they should change up after the 7mth of 07,but to be sure you can give your dealer parts dept the vin#and they can double check for you.

[Redstuff]

I really need to spend more time here...I'd heard about the spark plug issue after one of the guys at work had his 3rd plug on the passenger side blow out on him pulling his 5h wheel, and the place he got to fix it (not a Ford dealer) said "Oh yeah! Common as water!" They'd done something like 50 of them (and we're talking in a town with a pop of about 3500 plus the surrounding farms) and even had special tools they either bought or had made to make it easier. Now, if the '08's don't have this issue, I guess I got it made! I was thinking once the lease was up even though I'm super low mileage, I may just trade it for a newer one (might anyway since more power is coming!). Now I guess I can rest easy knowing I won't be having that issue in or out of warranty! Phew! Good stuff to know!

[Jon]

I just bought an '07 with 55,000km, A buddy of mine has done the plugs on a few 5.4s in the past, should i let him try, what if we run into trouble, would warranty still help me out?
I asked my local mechanic, and they won't even touch them,after reading all the above,I don't blame them

[gilligan]

i just had my spark plugs done in my 97 4.2 we had trouble with one plug only now its o2 sensors

[FX4Ranger]

We have had instances of the 5.4 spark plugs breaking when being removed. Ford provides us with a special tool to remove them, however if the rear plugs break it requires removing the head or the if both break remove the engine. Scheduled maintenance suggests inspection or replacement at 100,000 or 160,000 kms depending on model. I reccommend you have the spark plugs inspected before the warranty expires. Either way it is an owner cost to inspect/replace but should they break warranty covers to remove them, saving a potentially costly bill.

ive done that job several times, dealing with broken and not broken plugs. i had an 04 with 124kms and all 8 came out ok, the trick is to do alot of intake cleaning and letting it sit over night before attempting. i also had one at 160kms 7/8 broke only #3 came out in 1 piece... you dont need to remove the engine or anything to get to #7 and #8, get the tool from Lisle, its the best one, makes it stupid easy to do this job. to get at 7 and 8 just pull the pcm off the firewall and put it off to the side. its a long job to do 7 extractions, but not hard if you have the Lisle tool.

[stsjuice]

:icon_confused:I have an 06 f150 got 95000 on its got the extended powertrain on it,up to 100000km,.Does anyone know if this warrenty would cover me if they broke coming out.

[Greg Coleman]

I know this post is old but I'm having trouble with miss fire right now.Now Ive done a bit of research and so on and I believe the plugs should be changed at no later then 100,000kms and I have checked with many ford dealers and no the drive train warrenty will not cover a broken plug as this is considered maintenance on your vehicle.So if your getting misfire like I am it is likely the coil pack.So I have to run the codes and see what cylinder is misfiring and change the coil pack and change all the other boots on any remaining coil packs.