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View Full Version : Fords worst, idea 5.4 3V Spark plug defect


Dennis Reinhart
02-06-2009, 03:56 PM
This week we had a Ford Expedition, come in with a engine miss, it had 138 K on the motor, and these engines have the cam phasers that are prone to failure and the lifters, so Steve removed the valve covers and we found a broke rocker parts of a lifter and the lobe gone off the cam shaft.

http://web.iwebcenters.com/reinhartautomotive/images/session/00-00-1233959785-IMG_2339.jpg

http://web.iwebcenters.com/reinhartautomotive/images/session/00-00-1233959843-IMG_2348.jpg

So I found a 06 motor with 33k on it. This SUV has the 5.4 3V these the engines came out with a very flawed spark plug, and as you will see below it is one of the poorest engineering design flaws, this spark plug has a shield extended past the threads, and what happens is, carbon will build up on the sleeve and when you take the plugs out, it can snap off in the head, it takes a 500.00 Rotunda tool to get them out or the head has to come off. I later found out Mac tools sells this kit for 125.00

http://web.iwebcenters.com/reinhartautomotive/images/session/00-00-1233961200-IMG_2347.jpg

As shown what happens is the lower half with the porcelain electrode snaps off in the head, the first thing you have to do is glue a pin in the porcelain let it set up, then use a spacial extraction tool to get the porcelain out of the metal shell

http://web.iwebcenters.com/reinhartautomotive/images/session/00-00-1233960218-IMG_2352.jpg

http://web.iwebcenters.com/reinhartautomotive/images/session/00-00-1233960288-IMG_2351.jpg

Once you have that out then you run a spacial tap to thread the shell then insert the extractor to pull the sleeve out.

http://web.iwebcenters.com/reinhartautomotive/images/session/00-00-1233960398-IMG_2349.jpg

Luckily we had this happen with the engine out it made things a lot easier, of course Ford changed the design in 07, but for those owners that have these engines a top engine de carbon is mandatory before a tune up, with still no guarantee you can safely get the plugs out with out snapping off.
Raudermaster
02-06-2009, 03:59 PM
Figure's, my truck is one year off. I've heard about this problem though before.
Dr Caleb
02-06-2009, 04:35 PM
Dang! I've got an '06 F-150 with the 5.4.

Hmmmm, lease is up in May - guess I won't be buying it!
Seneca
02-06-2009, 05:11 PM
Thanks for the post dennis! I to have heard of this flaw, One of the ford classes i attended recomended soaking the spark plug holes with a special type of spray, Cant remember name of the top of my head. Letting it set over night, Before attempting to change plugs they also said it would be a good idea to change the plugs every 30k miles, and use antiseize, I'm keeping my fingers crossed, my F-250's got 80k miles Gonna change mine this spring, Seneca
scruff
02-06-2009, 05:24 PM
what brand of plug is that there? would switching to a better made plug say maybe Bosh or something simillar would they perhaps not break as easy?
stangracr
02-06-2009, 05:35 PM
I hear ya Dennis. I have done tons of those. I work at Thoroughbred Ford here in Kansas City. Terrible design. I have removed plugs from a 38,000 mile truck and had 3 plugs break. Soaking them in Kroil helps sometimes. Gotta admit the tool works great.



ed
RoyLPita
02-06-2009, 06:36 PM
Are you doing anything with the old motor?
Fourth Horseman
02-06-2009, 09:56 PM
The 3V S917 Mustang GTs have been having the same type of problem with plugs. At about 10,000 miles I pulled mine and replaced them with after-market plugs that are all one piece. It's just way too scary to leave those two-piece plugs in for very long. If they get carbon buildup they can be very tough to get out and you run the risk of breaking them in half.
ctrlraven
02-06-2009, 09:58 PM
A lot of 5.4 3v owners are steaming after they find out how much it cost to change the spark plugs, it's ridiculous.
ChiTownMaraud3r
02-06-2009, 10:26 PM
Thanks for the great insight post Dennis, it's good to know this.
RoyLPita
02-10-2009, 06:45 AM
Are you doing anything with the old motor?

Dennis,
Answer this, please.
Dennis Reinhart
02-10-2009, 07:37 AM
there is A 900.00 core charge if they do not come and get it its mine
RoyLPita
02-10-2009, 07:56 AM
there is A 900.00 core charge if they do not come and get it its mine

Thanx for the Info.
Marauderjack
02-10-2009, 04:06 PM
What's the point of the crazy plug design anyway??:confused:
lastdaze04
02-10-2009, 05:55 PM
What brand and what part number of this particular brand are you using. Inquiring minds want to know.:confused:
Rick


The 3V S917 Mustang GTs have been having the same type of problem with plugs. At about 10,000 miles I pulled mine and replaced them with after-market plugs that are all one piece. It's just way too scary to leave those two-piece plugs in for very long. If they get carbon buildup they can be very tough to get out and you run the risk of breaking them in half.
Dennis Reinhart
02-10-2009, 06:16 PM
What brand and what part number of this particular brand are you using. Inquiring minds want to know.:confused:
Rick


I would use Brisk
Fourth Horseman
02-10-2009, 09:43 PM
What brand and what part number of this particular brand are you using. Inquiring minds want to know.:confused:
Rick

I'm now running Champion double platinum plugs (Part #7989). I've had them in almost a year now and have good results so far. Here is the TSB on the issue, it's for the trucks but is the same for the Mustangs:

http://www.fcsdchemicalsandlubricants .com/fad/tsb/0819.pdf