Just want to point out; this is a plug problem but only with the 3 valve engine.
The 4.6 and the older 5.4 do NOT have this problem.


People read these threads when they are thinking of buying a truck, see everyone posting about plug problems, and do not do the research to find that it is only one engine, in one configuration.

I've had two people start telling me about how I can't change the plugs in my truck, etc. My truck is a 4.6, and changing the plugs is about the same as any other vehicle.

5.4 3 Valve is the one to worry about. And I would think that changing the plugs every 25-30k miles would keep you safe.

But I would not buy a used 3-valve without proof it had new plugs recently.
Sorry.
Chris

 

why is it only ford has this issue, its a clear design flaw that they need to address

I am no "ASE" certified mechanic, but I have been changing spark plugs since the '60s and never had such issues, its not like this is rocket science

aluminum heads are not a new technology, my buddy's 1969 camaro had an aluminum head 427 and never had issues

 

This is what Ive been trying to say the entire time. Spark plugs are not new technology and neither are aluminum heads or OHC valvetrain for that matter. So it seems like we are digressing in the auto community here. Auto manufacturers never had these issues in the 60-70, yet its nearly 2007 and we have to deal with this. And it just adds insult to injury when uninformed try to tell you that there is no problem.

Its a poor design, I think we all can agree on that. Ford should realize that and take responsibility for their poor deisgn. This is really going to kill used sale market for these truck for anyone that knows about it. A simple routine spark plug change can turn into a $1600+ nighmare. Maybe its just me but I find this pretty disturbing....

 

So we should change out our plugs every 30k miles? Ive got 35K and I know they have never been changed. The longer they stay in there means a greater chance of them seizing up right?

 

That's how it seems right now. I am not taking any chances.

 

Don't necessarily need to change the plugs, since they are quite expensive compared to all other engines. But, more or less just remove them and lube the extension under the jam nut. For the guy talking about torsional loads and ratchet extensions, it's not a snapping issue but more of a seizure problem. Sometimes the nut comes completely out, but the extension stays in the head. The guy speaking of a $1600 quote was getting a deal. My dealership quoted me $2400, and removed my engine and transmission at 53K mi because of a TUNE UP! To add insult to misery, I'm now missing a large rubber stopper on my trans bell housing, wire harness clips are broken, leaving wires draped across the engine now, AND they didn't even put my exhaust system back in all the hangers. All this and they even had my truck in the shop for 18 days. There's no excuse for the poor service my truck has received. Shame on you Ford for not owning up to this fiasco.

 

Ford Quality is JOB #1. Id be pissed to man. Im dreading changing my plugs. Frankly I dont have the time or patience to mess with the headache and worry of pulling them myself. I also dont want to pay the dealer the ungodly amount they are asking to replace them, and then possibly be stuck with the bill if they do break one. Its a lose lose situation either way you look at it. Ford's lack of response to this major screw up is really disturbing, and any blue blooded fan should be furious and not accept it and just bend over...

 

If my truck had this problem I would be suing Ford. But to be totally honest and fair, I don't think Ford is at fault.

They tested and didn't find the problem. No way would they market it if they had.

Everything I have read, seen, heard from technicians on this problem leads me to believe it is technically a fuel problem. The design team verified that there was no problem up to 100k miles. However; where they went wrong was fuel blends have changed dramatically in the last 3-5 years.

The fuel we use today in 50% of the country is completely different than the fuel Ford tested with, and expected. The fuel has way too much alcohol, way too many weird additives.

The plug extensions look 'rusted' not sized or damaged by combustion.

I suspect people in areas without blend gas are not going to experience this problem.
That does not excuse Ford, just puts it more in perspective.

The idea that Ford just decided to build-sell these engines knowing there would be this problem, is in the silly conspiracy class like the WTC was brought down by dynamite and Mark Fuhrman killed OJ's ex...

However, where Ford is blowing it BIG TIME is not coming out with a replacement plug with a better material/finish and not recalling the trucks to install this better plug.
If they don't do this soon, it's gonna hurt worse than the tire fiasco.
Remember, those plugs are being used in lots more than just the F150.
Chris

 

coming from a former ASE mechanic........i never broke a plug...worked on GM and Honda's.....to include those Fiero's!!! and if I "broke it" removing somethng.... i ate it. you shouldn't have to pay for something a mechanic breaks!!!!!!!!

 

Then you don't really know why the plug breaks. Totally different plug design.

 

Just a thought - the fact that plugs came out at 25K miles or 30K doesn't prove they would have ever been stuck at 50K or 100K. For example, IF the problem is actually due in part to slightly undersized thrreads in the head, and slightly oversized threads on the plug, then it will be just as bad whenever you try to get them out the first time. So in that case, if your truck doesn't have the problem, it probably never will. If there was a thread interference problem, it would probably never happen after the plugs were pulled out, since thread wear will probably take care of any interference problems.

And IF the problem is due to gunk buildup or rust buildup, how does anyone on this thread know that 30K is a magic number - all it does is give you a chance that the warranty will pick up the tab. I'd suspect the gunk or rust reaches it's maximum way before 30K.

I'm not saying that the plug design isn't a problem - but I really doubt that anyone (possibly including Ford) knows exactly what caused the problem, and I doubt that there is any magic to pulling plugs at any certain mileage. For those that have replaced them once, I'd say leave the new ones in for the normal service interval - they'll come out. For those that haven't replaced them yet, do whatever feels right to you, but mine are going to stay in until the normal interval. I haven't looked it up, but if it's 75K then I have about 2-1/2 more years before I need to worry, and if it's 100K it will be more like 2010, and by then people will know how to deal with it, and it won't be any different then than it is now.

There, that should stir the pot!

 

This thread has all you guys ever wanted to know about plug issues.
https://www.f150online.com/forums/sh...d.php?t=214810

 

What makes you think that your plugs will last 100k miles? Im not sure why ppl expect something like a spark plug to last that long in an internal combustion engine. Sorry to burst your bubble there. Hell Im having detonation problems at 24k miles, so I know my spark plugs could probably used replacement.

 

Good point, but I think I'll feel all warm and cozy inside doing mine early.

 

You should read the threads on this before expressing an opinion. Not slamming you, but you obviously have not understood the problem. The plugs that are pulled by 20k miles may 'creak'. By 30, some of the ends separate. They do NOT SNAP OFF. This has nothing to do with the threads. Period. Nothing.
This is the really long thin shell extension that covers the plug nose. This is so the plug firing point is way out into the stream from the intake valve.
This shell 'rusts' into place, thus making it very hard to remove the plug. This extension is below the threads, in a passage in the combustion chamber.

When this long thin shell has enough rust, corrosion, build up, whatever on it, the plug can not be removed as the shell will not turn in the passage in the combustion chamber. The 'solution' is to heat the engine up slightly, unseal the plug by turning it a fraction then letting penetrating oil go down PAST the threads and break loose the shell from the passage in the combustion chamber. Then you can unscrew the plug.
The ones that break the plug, the plug is busting because the area below the threads, the shell, is not turning. Thus you snap the plug in two, leaving the shell and some of the ceramic the shell is bonded to, in the hole. This you have to extract.
The longer the engine runs, the more this build-up continues.
Plugs changed every 20k miles would have no problem at all. No one has experienced problems if the plugs are changed early enough.

If the plugs were easier to get at and/or cheaper the solution would be change them every 20k.
The problem is the plugs are expensive and quite slow to change.
The real solution will be to make the nose out of some substance that 1. Won't corrode. 2. Won't allow build-up.

The problem is that plating them with, say, iridium, or hard chrome, would drive the manufacturing cost of the plugs up to about 10-15 bucks each. That would bring the retail up in the 50-60 buck a plug range. Not gonna happen.
They need to find a way to build-up proof the nose shell for under 2-3 bucks a plug. They have not found that yet.
Then Ford will have to spend upwards of 300,000,000 dollars recalling the 5.4 engines. Probably closer to a billion. So they are scared to death of this and will probably stonewall till a court orders it. That way, no one at the top is responsible for spending that much money, with no backend.
Sad that it must be this way.
Chris