I'm gonna replace the plugs in my mom's '05 Expedition pretty soon; I think I might try a few different experiments with it, removing them hot or cold, spraying some penetrating oil or something into the plug wells, and whatever else I can think of when I get there.

 

This is my first post on this forum

Anyway, I've been reading all about this plug issue and decided to change the plugs in my truck (2004 FX4 S-Crew). This job was super easy!!!

I ordered the special tool from national warehouse Clicky-Clicky

On the drivers side the only thing you need to remove is the air box (that thing is huge!!), on the passenger side you need to remove the PCM and the bracket that it's mounted on (note: a monkey can do this), then BAM access like a PIMP on Tuesday! It took about 2hrs (including the obligatory beer chug ).

After changing all the plugs the truck idled better. I will be doing this work every 30K to assure that nothing goes wrong. Anyone that thinks they can go to 100K without changing the plugs is asking for it, but hey...that's not me !!

Have fun!!!

 

2004_FX4, Glad you had an easy out. What was your mileage?

jpdadeo, I will be looking into those Autolite plugs for my next change out.
So it seems the colder plug is a better choice with our tunes. Since I only have the Xcal 1 I will be asking Mike if he should update my tune because of the colder plug. Here in Cal we can only get 91 octane and that sux. Better than 87 but I wish we had 93. The gas out here changes by the season. So far the Union 76 has kept my plugs clean.

bluejay432000, maybe your local independent was really much worse than the Exxon your trying out? I stay away from independents and Arco. It seems they dump an inordinate amount of alcohol in their station tanks to capture the water. For me price is not a real issue. I buy what I think is best for my truck. I've run my 91 tow and 91 perf tunes for the past 15K miles. Who else you got in yor area for gas? Try them after you log Exxon.

 

I had 29500 mi on it. I picked up the plugs at Murray's discount auto stores for $5.99 ea.

A couple plugs made a lot of creaking noise when I was pulling them out (mostly on the drivers side bank). But other than that, no issues.

 

A note of thanks to you guys for your information, analysis, and write-up about the plug change. I just finished changing the plugs in my 04 5.4l, and with your information, the job went smoothly. After 25,700 miles, the plugs did come out with some squeaking, and took some effort to break loose, but then they eased out. Each one came out with surface rust on the extension of the plug.

I took your advice on the dielectric grease and antisieze compound, and now I feel much better! Thumbs up to you guys and this forum for helping out so many members!

The job's done!

 

You hit the nail right on the head Spark plug issue is back

 

Oh no. Not this crap again.

 

[QUOTE=tardman91]Oh no. Not this crap again.[/QUOTERead 2004 3v 5.4 post

 

OK, Should i wait to change my plugs or should i do it now???

Seriously, i did take my truck in for the rough idle and the Service Manager said it was normal. I wonder if he knew about the plug issue then....
I bet i have a screwed up plug(s). Decisions decisions.....

 

Since when is a rough idle normal? Mine does not idle rough. Oh darn, is the spark plug issue still here? I'll sit back and watch this one.

 

Well I spent 2-3 hours reading all 31 pages. What a nightmare. I endured the blown sparkplug ordeal common to the 97-03's and now this just when I was thinking about up-grading to a newer improved 05. I guess I'll wait and see how this gets resolved.
Here is my summary of the excellent job of posting information and ideas done by other forum members.
Page 2 Post #26: a good picture of new plug. The first unthreaded part below the threads is there to align the plug threads with the head threads and prevent cross-threading by the robot. A good idea for aluminum heads.
Page 13 Post #192: a good plug diagram showing the cold seam between the ground shield and the jam nut which allows the creation of a "spinner" if the shield is siezed and the jam nut turned anyway.
Page 22 Post #327: Some good advise on plug changing.
Page 24 Post #350: Very disturbing video of "spinning" plug.
Summary IMHO: I think the problem is in the machining of the hole in the head for the ground shield. If the hole is a fraction too small or not aligned with the threads up above then a robot screwing in the plug will cause the shield to bind and then continuing to turn the plug might cause the jam nut to break free but still push everything on down and seat the plug. Now you have a "spinner" that will have a compression leak around the porcelain like it shows on :Page 25 Post #362: If your plugs come out hard or creaking it might be wise to ream the ground shield hole with emorycloth (or something) until a new plug will freely screw in down to the seat. Back to waiting to see what Ford does.

 

I've read all this broken spark plug chat and I'm scared. I don't wanna break one myself, but if Ford dealer tells me SOL. I'm gonna be pissed. Other than that, everyone is talking of rust on this little do hickey under the threads. What about the rust and carbon deposits coming off during removal of the plug? It's gonna be sitting on top of your pistons, scratching the heck out of your cylinder walls. The more you remove and clean them the more deposits you'll be leaving behind causing compression loss. Right? Is anyone else concerned about rust in the combustion chamber? Hopefully someone sees this and makes the plugs in a stainless. They would have the 04- present 5.4L 3V market cornered. What do I know, I'm just a PAINTER.

 

Ford temporary solution to possible spark plugs seizing up and breaking off in the head is to soak the plug well with a generous amount of Kroil penetrating oil and work the plug back and forth until it gives up. I'll be trying this method myself soon on my mom's Expedition to see how it works out.

 

That's pretty much guaranteed. I'm SURE Bosch or similar will come out with something just like that.

 

I don't think I ever want to change my plugs after reading all this...I think I will just leave them in for the 100k miles...by then I will probably want to trade it in anyways......who knows...if I do keep it longer than I will have a good shop do it and if they screw something up, they WILL pay!