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  #1  
Old 10-26-2006, 11:33 AM
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Cant remove spark plugs

Hey, I'm trying to replace my spark plugs for the first time on my 5.4L V8. I got the boot off but I cant seem to get the spark plug socket to grip on the spark plug. Its almost seems like the spark plugs in there arent 5/8" But that's impossible ... right? When I look down the hole to the spark plug I dont see any debris or obstructions. It does look like the spark plug is almost round in shape... but not like its stripped, just more round. Any help would be great. I've tried 3 plugs so far all with the same result.
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  #2  
Old 10-26-2006, 11:50 AM
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It sounds as though your plug socket is not fully engaging the plug. Sometimes it's because of the rubber gasket in the socket itself is too close to the front of the socket.

Verify you are using the correct socket and that you have full plug capacity by mounting the socket on your wrnech and installing one of you replacements plugs into the socket. You should see your problem.

Joey
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  #3  
Old 10-26-2006, 12:19 PM
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Ok so I tried a 9/16" socket and it fit perfect. I pulled the spark plug out and it looks like I only got half the plug out ... Now what do I do? I'm afraid I have a serious issue here. Here is a picture of the plug I pulled out.
Click the image to open in full size.
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  #4  
Old 10-26-2006, 12:20 PM
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*** EDIT - Aww crap, Hozer, you posted first ***

You shoulda waited - there is a lot of advice on the board about doing this properly... search.
You done broke it off. Now, you'll need the special tool and Ford's procedure TSB to remove the remnant. Sorry about your luck, man.
=======================================
Hi Hozer. Hey, nice handle

Anyways, Joey is right, because you'll see you are using the wrong size socket.

The 5.4 3V V8's use a 9/16" plug.

BTW - Didja catch up on all the reading on the spark plug change advice?

I recommend you do so - may save you some grief.

Good luck.

Cheers
Bubba

PS - nice to 'see' you again, Joey

Last edited by MGDfan; 10-26-2006 at 12:30 PM.
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  #5  
Old 10-26-2006, 12:26 PM
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Well, that's not good. If you'll search the '04-Present forum, there's a lot of grief and drama about changing plugs in the 3V engines.

With where you are now, there's a couple options; the best would be to get the truck to a dealer where they can use the removal tool and get the insert out without removing the cylinder head. If you don't want to do that, try soaking the insert in your favorite penetrating oil...not a lot, just a spritz or two, then disconnect the injector for that cylinder and run the engine 'till it gets hot. Hopefully, the aluminum around the insert will expand a bit from the engine heat and compression pressure will pop the insert out like a cork out of a champagne bottle. I've heard that this works, but I've never tried it personally.
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  #6  
Old 10-26-2006, 12:33 PM
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I did do a search before I started but aparently I didnt look hard enough. I just now found a thread about the sparks breaking off. Sounds like I'm up S#$% creek.
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  #7  
Old 10-26-2006, 12:35 PM
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Can you post a pic of a new plug right next to the one that is broken.

I just changed my plugs on my 02 5.4 2 valve motor and they look like normal plugs. I guess the 3 valve motor must have some weird looking plugs to break off like that.
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  #8  
Old 10-26-2006, 12:37 PM
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One or two guys have made a tool to extract the stem. They had write ups in the sparkplug threads. If you are not careful though and not an experienced mechanic, I would recommend getting the truck to a dealer.
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Old 10-26-2006, 12:51 PM
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Can you send me a link to one of these write-ups? I must be mentally challenged because I cant find them using search.
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  #10  
Old 10-26-2006, 01:02 PM
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here is the thread Mark another one on the wall for a sparkplug broke off in a head

Look at post number 92, then for the other plugs, you need to look at #70 and #85. Good luck.
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  #11  
Old 10-26-2006, 01:04 PM
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Quote:
Originally Posted by RacingJake
Can you post a pic of a new plug right next to the one that is broken.

I just changed my plugs on my 02 5.4 2 valve motor and they look like normal plugs. I guess the 3 valve motor must have some weird looking plugs to break off like that.
The 3 valve has the extention. Abilene Texas or Kansas?
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  #12  
Old 10-26-2006, 01:10 PM
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The cutting horse capital of the world...........Texas

I found a pic from over there

Click the image to open in full size.
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  #13  
Old 10-26-2006, 01:13 PM
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Quote:
The cutting horse capital of the world...........Texas

We lived for about 26 years in Abilene, Tx, left in 1991. Came out there to go to school and stayed. Was a good place to raise the kids. Job necessity required moving to Fort Worth. still know lots of folks there.
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  #14  
Old 10-26-2006, 01:17 PM
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Now what moron designed that..................

I guess before you install new plugs you'll need to get them tig welded.

Now don't tell me that long shaft goes that deep into the combustion chambers or maybe the plug doesn't go that deep in the mounting hole??? so you have short boots as compared to the 2 valve motor?

I'd like to see a bare head and how the plug mounts in it.
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  #15  
Old 10-26-2006, 01:26 PM
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Quote:
Originally Posted by bluejay432000
We lived for about 26 years in Abilene, Tx, left in 1991. Came out there to go to school and stayed. Was a good place to raise the kids. Job necessity required moving to Fort Worth. still know lots of folks there.
Yeap if Dyess wasn't here the population would drop by half. Min wage or Dr wage's not much in between.

Most likely we have crossed paths at Wal-Mart

Not a bad town except for a few soccer moms that seem they own the road.

Whats funny is folks from Abilene go to Dallas/Fort Worth on the weekends and folks from Merkel come to Abilene. The grass is always greener on the other side
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Old 10-26-2006, 01:26 PM


 
 
 
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