Kool Aid........the only reason I said that was because I remember the first few post people made about this happening. People began to freak out, which they have good reason to, and a lot of other people were making fun of them worrying about it saying things like "the sky is falling".....That's why I said what I said, I'm sorry if I offended anyone, I was only trying to stick up for the people that were worried about this, including ME.

And those plugs in that pic look horrible. Do you do a lot of short trip driving JP? I just can't see why they are actually rusting up like that, you'd think with any distance of driving would burn the water off that is rusting those up. I'm going to lubricate my new ones with some HHS-2000 and take one out in 5,000 miles after installation and see if that stuff works. We have it at work, it is made by Wurth and comes in a spray can. It is some neat stuff, it comes out thin and dries into a high temp, high pressure grease. Here is the specs from their webpage if anyone is interested.

HHS-2000
Lubricant, resistant to high pressures and with high adhesive strength. Penetrates into tightest areas easily. Sets into a high temperature grease. Ideal for hinges, latches. Optimim penetration into the treated parts. Immediate evaporation of the solvent, resulting directly in a high adhesive force between lubricant and metal.

Synthetic lubricant
Adheres strongly to metal
Temperature resistant from -31°F to +392°F
Silicone free
Starts as penentrant, sets into clear grease
Long lasting lubricant
Resistant to water, salt, most acids & alkalines - PH neutral
Will not harm plastics or rubber

 

Not that I'm aware of. I've e-mailed some people in higher places and I'm waiting on replies from them.

 

I completed the plug change on my 2004 FX4 5 months ago. My plugs came out a little rusted, but nothing special. All of them came out with some creaking & popping (cold engine).

I used the 5.4L 3V specific tool with a metal pipe extention to get it to break free. You will need to remove the air box & computer for access.

I'll be chaning my plugs every 30K to avoid any problems.

 

Then u got ppl like my dad who get rid of their vehicles before the warranty expires.

 

I know this thread is old, but I don't follow this forum much. Is there any word on a fix? Or a new type sparkplug to solve the problem? Quintin?

 

TSB 06-5-9 outlines removal of broken plugs. If anyone needs it, I have a copy and can e-mail it to you.

 

Yes post it

 

There is no chance that it is just the specific plugs that Ford uses? Has anyone replaced the original plugs and on their next plug change found the rusted problem or were the new plugs ok??

 

I can E-mail it!

 

The "fix" is to remove the plugs with the engine semi warm. Loosen each plug no more than 1/4 turn and spray your favorite penetrating oil (Ford specifies Kroil - I prefer PB Blaster) down in the well, not a whole lot, just enough to barely cover the hex portion of the plug. Go get a cold beer and wait for 10-15 minutes to allow the oil to wick down the plug, then pull 'em. I've done several sets this way, and I've yet to break one.

ETA - And if the plug should break, there is a tool to remove what's left of the insert. I have not used this tool yet personally, but from what I've read from other dealer guys who have had to use it, it works well.

 

Mine were changed at the dealer and through a tsb at 20,000 and none broke. They all looked brand new.

 

Thank you Quintin For the info

 

Is Ford recommending a different plug for replacement? My truck is close to 14k miles and I hope to have this thing for 5 or 6 years and if changing the plugs early will help when it REALLY needs done then I'm all for it.

 

As always, thanks Quintin. You rock

I'll be doing this real soon and getting some antisieze on 'em.

Cheers
Grog

 

Again, its not the threads that are seizing, its the shaft portion due to poor design, so antisieze will not do anything.