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1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

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Old 03-31-2008, 07:25 PM   #41
hotairgypsy
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

did you try the needle nose pliers idea?
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Old 04-01-2008, 07:35 AM   #42
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

No, not yet. I'm trying to find a pair of long reach needle nose pliers so I can pull out the electrode I put back in there. I'll try and pick up a pair from Grainger today.
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Old 04-01-2008, 11:23 AM   #43
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Slightly off topic.... my '06 has a little over 6k miles on it. Should I just pull the plugs now and replace with the one piece plugs or wait? I don't want to go through this!
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Old 04-01-2008, 11:45 AM   #44
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

I have an 06 w/6000. I think I'm going to wait until it's got 15K on it before I do it.
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Old 04-01-2008, 08:08 PM   #45
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

I had the dealer pull mine at 15k and they all came out okay but the dealer said they were a bit tight. I had them put the originals back in with the anti-sieze. I just pulled them out today (1k later) and put in the Champions. So far all seems good after a test drive.

There wasn't a nice coat of anti-sieze on the plugs like I thought there would be when I pulled them. In fact, I was wondering if the dealer even pulled the plugs but the stuff that was on the plugs was greasy and it smeared when I touched it. But, there sure wasn't a nice even coat of anti-sieze after just a thousand miles so I'm wondering how good the anti-sieze will be on regular plugs after many more miles of driving. Maybe the dealer just did a bad job of putting the anti-sieze on but glad I have the Champions in. I gapped them to .045 and torqued them to 25lb. I put anti-sieze on the Champions, too, just for added piece of mind.


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Old 04-02-2008, 10:25 PM   #46
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

UPDATE: I was able to remove the ceramic insulator from the metal shield by taking a 12" piece of wire coat hanger, scuffing one of the ends and J.B. Welding it to the ceramic core by placing it through the hole in the center of the core. I made a home-made slide hammer by putting a kink in the other end of the coat hanger after first placing a heavy socket over the wire and then a 1/8" piece of plate steel with a hole drilled in the center to fit over the coat hanger wire.

However...the slide hammer did not work. This thing was stuck! I ended up placing a piece of 2x4 across the top of the battery and the intake manifold and prying against this with a crowbar. With enough tension on the core, it broke free from the metal shield. There was an amazing amount of carbon between the ceramic core and the metal shield (see the second photo of the ceramic core still J.B. Welded to the coat hanger wire). Also, see the last illustration below for a pic of the pry bar mock up.

Lastly...I tried to get the metal sheath out by using an 4 corner easy out. It didn't work. Tonight I gave in and order the "rotunda" tool Ford designed for the metal sheath removal. Oh well...I'll update when I get the sheath out...hopefully what I've done here will help others in the future. Oh yes...there will be others...



[IMG]local://upfiles/38521/BAAFE586BCCE481FA10D4DC1C2BF7A75.jpg[/IMG]

[IMG]local://upfiles/38521/3ECCCF2937674187A1294A442ADA5358.jpg[/IMG]

[IMG]local://upfiles/38521/75DDA9FA639A4592A430CC3D959C7948.jpg[/IMG]

[IMG]local://upfiles/38521/5BD36B57BBFC4DB6A31B1595FFC94F01.jpg[/IMG]
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Old 04-02-2008, 10:45 PM   #47
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

i think you did good...you have successfully removed the part that causes the expensive bill...now you just have to do the extraction so i would count this as a success
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Old 04-03-2008, 06:32 AM   #48
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Wow, you did great. That rocks. I appreciate your situation a little more after pulling my plugs and really seeing how small it is down there. Very nice job. Hope the rest goes a lot smoother.
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Old 04-05-2008, 08:20 PM   #49
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Well, I got the Rotunda tool today. Took me about 15 minutes to get the metal sheath out. Finally I'm done. The car is back up and running...very well I might add. Here's the cost of the spark plug change:

Spark Plugs = $60
Motorcraft Nickel Anti-seize = $17
Motorcraft Carb Cleaner = $7
Rotunda tool = $229
______________________________________
Total Cost to Change Spark Plugs = $313 + a whole lot of aggravation!




[IMG]local://upfiles/38521/BAF8ED98A39E405FA2E1D5E223EAAF80.jpg[/IMG]

[IMG]local://upfiles/38521/67A622CFB5F14ABD9805B4B183BFFB90.jpg[/IMG]

[IMG]local://upfiles/38521/011EEC3D9B9146EFB67656591E14009E.jpg[/IMG]
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Old 04-05-2008, 08:38 PM   #50
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Oh...and...thanks to everyone for their advice and support! By far...Mustangforums.com has the best support and feedback for S197 Mustangs...hands down! -Tim
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Old 04-05-2008, 08:50 PM   #51
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Dude!
Way to go Hicompression! lots of aggravation but YOU did it. Way to hang in there.
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Old 04-05-2008, 09:05 PM   #52
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Way to go Tim, you the man!
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Old 04-05-2008, 09:12 PM   #53
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Thanks guys! Not the best...but here's a pic of my '06 stang.




[IMG]local://upfiles/38521/84FD18C16DBE46A694FA88220C1FE756.jpg[/IMG]
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Old 04-05-2008, 10:24 PM   #54
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Ya know, it's kinda funny now; way back when I kind of started this discussion after I broke a plug in my '06 (following the TSB). I then had my car trucked to the dealer where they broke 5 more before the job was done. I had a couple of guys say this was all a myth, and that they had busted it because they got they're plugs out clean. All I can say is they should have bought a lottery ticket that day.
There's still a heck of a lot of 4.6's and 5.4's that are racking up miles and will eventually have to come in for a plug change.
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Old 04-06-2008, 07:57 AM   #55
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Quote:
ORIGINAL: Hicompression

Well, I got the Rotunda tool today. Took me about 15 minutes to get the metal sheath out. Finally I'm done. The car is back up and running...very well I might add. Here's the cost of the spark plug change:

Spark Plugs = $60
Motorcraft Nickel Anti-seize = $17
Motorcraft Carb Cleaner = $7
Rotunda tool = $229
______________________________________
Total Cost to Change Spark Plugs = $313 + a whole lot of aggravation!




[IMG]local://upfiles/38521/BAF8ED98A39E405FA2E1D5E223EAAF80.jpg[/IMG]

[IMG]local://upfiles/38521/67A622CFB5F14ABD9805B4B183BFFB90.jpg[/IMG]

[IMG]local://upfiles/38521/011EEC3D9B9146EFB67656591E14009E.jpg[/IMG]

Satisfaction of getting the job done yourself = priceless.

Glad you got it done. Very nice job.
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Old 04-06-2008, 02:52 PM   #56
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

good job man, at least you didn't have to pay $600 for the stealership to pull the head.
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Old 04-06-2008, 09:51 PM   #57
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

1 this will loosen anything, and I'll soak my plugs with it and let
you allknow how it goes
Click the image to open in full size.

2. if I break one ,Hicompression
is you tool available for loan?
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Old 04-07-2008, 07:40 AM   #58
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Quote:
ORIGINAL: Hicompression

Well, I got the Rotunda tool today. Took me about 15 minutes to get the metal sheath out. Finally I'm done. The car is back up and running...very well I might add. Here's the cost of the spark plug change:

Spark Plugs = $60
Motorcraft Nickel Anti-seize = $17
Motorcraft Carb Cleaner = $7
Rotunda tool = $229
______________________________________
Total Cost to Change Spark Plugs = $313 + a whole lot of aggravation!




[IMG]local://upfiles/38521/BAF8ED98A39E405FA2E1D5E223EAAF80.jpg[/IMG]

[IMG]local://upfiles/38521/67A622CFB5F14ABD9805B4B183BFFB90.jpg[/IMG]

[IMG]local://upfiles/38521/011EEC3D9B9146EFB67656591E14009E.jpg[/IMG]









That sheild looks amazingly clean. Wonder why it broke??/
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Old 04-07-2008, 09:25 AM   #59
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

Quote:
ORIGINAL: ShadyNinja
2. if I break one,Hicompression is your tool available for loan?
Seeing as how you're in Chicago, I'll loan it to you for $229 (which is what I paid for it).


Quote:
ORIGINAL: GidyupGo
That shield looks amazingly clean. Wonder why it broke??/
The shield was cemented into the head with carbon. After I got it out, I wiped the shieldoff before I took the pics. Otherwise it looked similar to the shields on the other plugs that I pulled out that didn't break. I've been told the rearmost cylinder on the passenger side head is the hottest cylinder on these cars, which is why the carbon was so agressive and the plug broke.
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Old 04-07-2008, 12:13 PM   #60
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Default RE: 1 Out of 8 Spark Plugs Broken After 96,000 Miles and Performing the TSB

why would one cylinder be that much hotter than all of the others? it can't be good for the engine to have an unbalanced displacement of heat like that can it? is it hotter enough that it would make sense to use a colder plug in that cylinder?
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Old 04-07-2008, 12:13 PM
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