The carbon doesn't seize it totally until it rotates more then 1/8th of a turn. When it rotates the carbon ***** up and wedges it in.

 

Never heard that before but it's very interesting. I've heard some on here do something where the engine is "decarboned". Anybody else know if this is done and so, if it's useful?

 

Pouring seafoam in is supposed to de-carbon the engine. I have never tried it.

Follow the procedure on the plugs... you shouldn't have a problem.

Spray the hole.. wait.. turn 1/8 turn.. spray a little more.. wait.. and remove the plug. On a warm engine. Can't go wrong there.

 

Thanks for the replies. Guess I'll wait a little longer before changing them. I'll check back about the issue in a year when more F150s get experience with plug changes.
Off subject, as a side note, was really impressed with the 4x2 Screw this weekend. Took it and a boat(16ft) down some logging trails to a pond to fish. 15-20 other trucks also went. Rainy and very muddy. I made it thru some pure hell(bottom outs, major ruts, the works). Two chevys found the ditch(go figure, light rearend). One old dodge as well. I didn't get stuck UNTIL trying to pull the boat out. Didn't have a ramp. Just stuck it in the deep end of the pond. Too slick at the bank, back tires downhill and very wet, soft bank. Better luck next time, but I was still impressed with the F150.

 

I just traded my 04 F150 with 27,000 miles on the clock. I feel sorry for the guy who buys that truck and has a spark plug snap off in the head. It really surprises me to read that people with 06's have over 30,000 miles. I only averaged 9,000 miles a year.

 

Did you have any experience with your 04' concerning the plugs or did you just trade to upgrade to a superduty? You must have a big pocketbook b/c those new diesels are a house payment. I drive about 40+ miles a day back and forth to work. Expensive for gas but I'm tall and don't want to be caught in a bad wreck in a small car. I'm curious about the diesel you bought. I've heard diesel engines aren't happy about being driven short distances and infrequent driving. Good luck though. I hope the 6.4 is better than the 6.0L Ford put out a few years ago.
Concerning the plugs though on these new 5.4L 3v engines, I only want to feel confident Ford thought it out better than what I'm reading on-line. I find it hard to believe that for 4 years, they have been putting these engines in their trucks and SUVs and don't realize or understand how much disaster awaits them when plugs and heads get damaged at routine plug changes, and come to find out, the Ford represented dealership service departments refuse to pay for damage they cause b/c of defective design. If this happens, I really hope this company goes belly up. 4 years of stupidity shouldn't go unpunished......

 

Why would they act like they know nothing about it when they really do? If I was a dealer and knew about it, I would say sure, bring it in, we'll have a look. That's puts more money into my pocket.

Did you ever think that maybe it isn't really that big of an issue? This board represents a small number of total F150 owners. They also tend to be more biased towards modding their trucks. So if 10 people show up with spark plug issues, does that mean there is a huge problem? Maybe, but not necessarily. Discussion forums like this make the issues seem more prevalent than they really are due to a main purpose of forums...to discuss and resolve problems with your truck. Users tend to show up to discuss problems and report problems they have found to make others aware.

Maybe the dealer is yet to do any plug changes on an 04+. Maybe they've done 10 or 100 or 1000 and never had an issue. Out of the 100's of thousands of 3 valve 5.4's that have been sold, if this was a huge issue, you can better believe the media would be having a blast reporting it in the news. My guess is that it is really not that big of an issue, and dealers have the TSB to know how to handle it if it is.

Now, will I change my plugs before 100k? Nope. Am I worried about it? Nope. If it is really a big issue, my thinking is that the dealers will be really good at fixing it by then. Might as well let them practice on other people's trucks. And, if it is going to cost me to fix a problem, I would rather just pay it at 100k instead of paying it at 30k, 60k, 90k... Of course, this is just MHO. Yours may differ from mine and that is fine...everyone's opinion will vary. I will run this truck just like my last. Do the scheduled maintenance when Ford recommends (maybe slightly before due to my towing)...they know a hell of a lot more about their trucks than me. It may it to 136k before being totaled by the guy that bought it from me. I'm not too worried about this one either.

 

I think you're right concerning the actual number of problems vs plugs changed with no problem. I hope at least. Thanks for posting b/c it gives me more confidence others here believe waiting may be the best way to go. I've always been, like you, the type to do maintanance when recommended. All the threads about plug problems have gotten my attention, esp since mine is an 05', probably the same plugs/set-up as the 04'. I look forward to hearing from others down the road after a plug encounter, whether good or bad. A pole a couple years from now might give us a better ratio of how bad this problem might actually be. In the meantime, I'll just

 

A question I have is, at what threshold ( e.g number of reported issues, warranty costs, etc) does Ford then create a TSB for? And design a special tool to use in that plug TSB?

To me, these things point to a growing and potentially MUCH larger report rate as these vehicles age.

What's most troubling is these have been no redesign of neither the head nor the plug across the 3 years this issue exists ('04 - '07 5.4L 3V, or the 4.6L3V 'stang).

Thoughts? Any insight on the '08 3V plug design?

thanks

 

As much as I don't like to agree with MGD (nothing personal buddy), I agree with him here 100%.

I work at a rather small shop compared to a Ford garage...We know of the problem and we've known of the problem for a long time. We see maybe 1 F150 per week at the most and we've probably only tuned up 10 04+ 5.4 F150's. The parts stores near us all stock a special repair kit because it's such a common problem.

I have personally never seen it happen in my shop, but a shop up the road had it happen to them and if the parts stores didn't have the heli-coil kit in stock, there would have been one p*ssed off customer.

--

Anyway, as un-common of a problem as it is as far as its relation to the total number of F150's out there, it's definitely a large enough problem that every Ford dealership should know about it. Now the guy you get on the phone when you call the dealership may honestly have no idea whatsoever of what's going on. Those service writers up on the counter write the work and give the work to the mechanics...the mechanic does the work, knows the problems, knows the fixes, and that's just how it is...the writer is the middle man and *usually* knows nothing about what goes on and most couldn't explain how to get your oil filter off if you called and asked them that over the phone to be honest. So if they said they don't know anything about this issue, I'd probably believe them. Go stop up at the dealership if you're that concerned. You bought a 40 thousand dollar truck, I'm sure the service manager will get his lead tech to talk to you for 5 minutes if you ask.

 

Since the part of the plug that seizes up is below the threads, I fail to see how developing a tool to remove them is even possible. It's not the threads that seize up. It's not the area of the plug above the threads that seizes up. It is the long shaft below the threads, inside the head, that freezes up, Any "tool" that addresses this issue would have to work from the inside the head. This issue, if it is an issue at all, is one that will require a redesign of those heads and/or plugs. Simply making that shaft below the threads slightly thinner may be the easiest answer, as the shaft will no longer bind inside the area of the head where carbon is building up.

 

There is a tool out there, I believe it is only for the retrevial of the broken plug so that they do not have to remove the heads to get the plugs out after they are broken.

I also see that this is going to get much more common once more of these truck start reaching the 100k mark when Ford recommends the plug change. Alot of people only put 12-15k on per year and that is now where new the recommended change interval.

As for me I'm undecided if I should change the plugs early or just say screw it and drive it. Now if the plugs where of a normal price I would go ahead and change them but as we know they are quite expensive.

 

Same here. I asked my dealer and he played dumb. I may just leave them and get rid of the truck before the required 100,000 mile change. Why should I run the risk, and chance that I'll be the one paying if they snap'em off.

 

Hmmmm, much less expensive to fix the head than buy a new truck. That is IF yours break off AND the tool to remove the broken plug doesn't work.

If you are going to get rid of the truck to avoid a possible (however slight) issue with the plugs, then you definitely have more money (or paranoia) than I.

Hey, why don't we all kick our kids out when they are 12 because I read on some forum somewhere that teenagers are hard to live with and might cost me a lot of money! (well, the money part is defninitely true)

 

Correct.

The tool has already been developed & issued to dealers. (Rotunda?)

That's part of my point (and question) - Ford went to the effort to do that, based upon how many reports? Would they do that, if the problem was trivial?

Freeky - search for the TSB on here if you want to see the tool & how it's used.

The 'sleeve' is smaller in diameter than the threaded hole (obviously), so it's possible to remove it without taking off the heads, in most cases.