Spark plug problem
11-20-2013, 02:08 PM
#22
Gentleman's Relish
Join Date: Feb 2005
Location: AZ
Posts: 13,090
I hate to say this, but it is a very common thing in the Ford 3v 5.4 engines. Usually at high miles, or after a number (3 or more) spark plug changes. I own a 98 4.6 and don't have the problem with that, but the newer 4.6 have PI head, which give more flow, but the thread area isn't as strong as the earlier 2v or 4v heads. This is why the 3v 4.6's blow plugs. That and over tightening the plugs when installing them. Twenty eight (28) pounds is all they use. Anything more is just asking for trouble.
Lisle makes a special tool for these broken plugs and a thread repairing kit. 65600 is the part number for the broken plug remover. OTC makes a special spark plug tool for the 3v also, so that there is NO flex are the connection joint on the plug tool. It is a one piece 9/16 socketed tool. When in comes to fixing the threads, there are numerous kits out there. Do NOT use one of the cheap kits or you will have the problem again, only the head will probably have to be removed the next time, if it blows again on the same hole. Use Time Sert inserts if you can. They are the best and most reliable on the market. Of course, they are probably the most expensive. The kit is the big price, but you can keep it for another time, or resell it to another member. Just don't use the cheapos. They will last no time at all, and they are just that, cheap crap.
Go online and check out the head repair on the 5.4's. These 4.6 heads are just like them. YouTube has a bunch of videos on this happening. The F150 forums are full of spark plug blow out horror stories. They aren't that bad to fix, just a bit time consuming and can be a bit expensive. You might be able to rent the tool from a tool rental shop, but that depends on where you are. I'm sure Advanced isn't going to have it for a loaner, but you could check. That would be the ticket if they did.
Hope that helps clear up the plug question.
Lisle makes a special tool for these broken plugs and a thread repairing kit. 65600 is the part number for the broken plug remover. OTC makes a special spark plug tool for the 3v also, so that there is NO flex are the connection joint on the plug tool. It is a one piece 9/16 socketed tool. When in comes to fixing the threads, there are numerous kits out there. Do NOT use one of the cheap kits or you will have the problem again, only the head will probably have to be removed the next time, if it blows again on the same hole. Use Time Sert inserts if you can. They are the best and most reliable on the market. Of course, they are probably the most expensive. The kit is the big price, but you can keep it for another time, or resell it to another member. Just don't use the cheapos. They will last no time at all, and they are just that, cheap crap.
Go online and check out the head repair on the 5.4's. These 4.6 heads are just like them. YouTube has a bunch of videos on this happening. The F150 forums are full of spark plug blow out horror stories. They aren't that bad to fix, just a bit time consuming and can be a bit expensive. You might be able to rent the tool from a tool rental shop, but that depends on where you are. I'm sure Advanced isn't going to have it for a loaner, but you could check. That would be the ticket if they did.
Hope that helps clear up the plug question.
The New Edge mustang 4.6L 2-V motor (99-04) had the same type of heads as the 5.4L and 4.6L F-150's and suffered from the spark plug blow outs. Not the S197 with the 4.6L 3-V motor.
The S197 heads came in two flavors Version 1 (05 to early 08) and Version 2 (mid 08 to 10). Version 1 looks nothing like the 5.4L triton head plug. Version 2 looks similar to the 5.4L plug but still, not the same design.
The S197 common problem for Version 1 of the plugs is the plugs breaking (in the head) when removing them for servicing/replacement due to carbon build up on the long unthreaded nose they have. It basically glues the plug into the head.
Version 2 fixed that by going with a more traditional style plug. Version 2 however requires a different head and different coil. Version 2 has brown coil boots, Version 1 has black coil boots.
New Edge mustangs did suffer from plug blow out. The S197, first I've heard of it being an issue. Also note that the first versions of 3V engines in the F-150 have the same issue as the first versions of Mustang 3V engines (plugs breaking in the head).
Last edited by Derf00; 11-20-2013 at 02:12 PM.
11-22-2013, 02:58 PM
#25
2nd Gear Member
Join Date: Oct 2009
Location: Anchorage, Alaska
Posts: 459
Derf00.....I don't think so. Here is something for you to think about. There is a big class action suit for this and the broken plug deal. Here is the info on the broken plugs. There is a section on blowing out also in the complaint. It covers the 4.6 Mustang. I worked for Ford, and we had a ton of problems with the 4.6 in the 05's and 06's. I don't make this crap up. I just couldn't post the whole complaint. It is many pages of testimony and such.
Reason for Ford Spark Plug Class Action Lawsuit
The Ford spark plug lawsuit claims that spark plugs in certain Ford models break during replacement. As a result, broken pieces or fragments of the defective spark plugs get stuck in the cylinder head, which has led to expensive repair shop bills in order to remove the broken spark plug pieces and/or repair damage to engines. The Ford spark plug class action lawsuit is a defective product lawsuit.
Ford did issue a Technical Service Bulletin (08-7-6) in 2008 which provided instruction (11 pages!) on how to properly remove the spark plugs.
Ford Models included in the Ford Spark Plug Class Action Lawsuit
The “class” for this lawsuit would include owners of the following Ford, Lincoln and Mercury models:
Ford
2005-2008 Mustang
2004-2008 F-150
2005-2008 Expedition, F-Super Duty
2006-2008 Explorer
F-53 Motorhome Chassis
2007-2008 Explorer Sport Trac
Lincoln
2005-2008 Navigator
2006-2008 Mark LT
Mercury
2006-2008 Mountaineer
Reason for Ford Spark Plug Class Action Lawsuit
The Ford spark plug lawsuit claims that spark plugs in certain Ford models break during replacement. As a result, broken pieces or fragments of the defective spark plugs get stuck in the cylinder head, which has led to expensive repair shop bills in order to remove the broken spark plug pieces and/or repair damage to engines. The Ford spark plug class action lawsuit is a defective product lawsuit.
Ford did issue a Technical Service Bulletin (08-7-6) in 2008 which provided instruction (11 pages!) on how to properly remove the spark plugs.
Ford Models included in the Ford Spark Plug Class Action Lawsuit
The “class” for this lawsuit would include owners of the following Ford, Lincoln and Mercury models:
Ford
2005-2008 Mustang
2004-2008 F-150
2005-2008 Expedition, F-Super Duty
2006-2008 Explorer
F-53 Motorhome Chassis
2007-2008 Explorer Sport Trac
Lincoln
2005-2008 Navigator
2006-2008 Mark LT
Mercury
2006-2008 Mountaineer
Last edited by akdoggie; 11-22-2013 at 03:02 PM.
11-22-2013, 03:16 PM
#26
2nd Gear Member
Join Date: Oct 2009
Location: Anchorage, Alaska
Posts: 459
If you check the F150 Forums, there is a bunch of them, all have the plug breaking and blow out problem well documented. It is a big thing. I bleed Ford Blue, and this isn't a big thing to me. It is an inconvenience admittedly. I can repair it, if it was to happen, so I'm not worried. One of the taxi fleets, has taken all their Crown Vics and had the heads all redone, so it doesn't bite them in the *** later. I believe it was Crownvic.net that really brought it to light on the car side of the issue. It is a basic Modular design issue.
http://www.crownvic.net/ubbthreads/u...Number=1897815
http://www.crownvic.net/ubbthreads/u...Number=1897815
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