I know many a threads have been started about the 5.4 3v motors concerning the plugs snapping off in the heads ruining them. I've been sitting on having them pulled and inspected due to being scared I'll screw something up. So, I've been calling as many Ford dealerships here in Geargia to see what Ford is telling them and what's being done to address the issue. I was shocked to hear from 6 of the 7 dealerships/service centers that they haven't heard of a problem with the plugs freezing up or snapping off. What a crock of crap. I mean really...... I asked them from different angles to try and get them to admit they KNOW about the issue. It's apparent they do b/c they avoid the issue right from the start with very short prepared responses. I hate dealerships and their jackleg mechanics who try to hide behind the blue oval sign instead of being honest with people. I'm more likely to keep my truck and work thru the issue if told the dang truth instead of them boldface lying. If the forums here and other sources all over the internet talk about these plugs and there is listed a TSB for the removal of the plugs and "fragments" if broken, then I know the jackasses at the stealership know about it.
After venting here much, I'm curious to recent attempts from owners who have had their plugs replaced. Also curious about how many people are having them pulled/checked early and the neverseize application. I hope some later mileage f15o owners will chime in on their experience.

 

First off:
What year is your truck?
How many miles?

Second:
Try one yourself.

1.Get some Kroil or PBlaster.
2.Spray down into hole liberally.
3.Replace COP.
4. Wait about 1-2 hours.
5.Drive around the block and let the engine get warm.. NOT HOT!
6. Try to remove the first plug on the driver's side. Its the easiest.
Use slow and constant pressure while trying to remove the plug.. Quick bursts or torque on the wrench will most likely snap it off.

It's not hard to do yourself if you have basic mechanics knowledge.

If not, take the truck to a TRUSTED mechanic and let them do it. make sure they follow the instructions I just gave you.

The hardest plug to get to is the rear passengers side plug. you have to remove the PCM and the bracket holding it first to remove the plug.

Go out there and get your hands dirty.

 

khendrix summed up the steps well. Take your time and have a buddy help you out. You can definitely do it by yourself but having a competent person to help you out makes it a ton easier. I just took mine out at 30k. I read the forums a million times and for my situation (2005 @ 30k miles), if I took my time and followed the right steps I should be good. So I did it.

Note: Warming up your engine is key. I used a torque wrench to remove the spark plugs to ensure I never put more than 25 ft. lbs on it. On a cold engine, some of the plugs wouldn't come out at 25 after I warmed it up it came off at less than 20. Also buy a few extensions and joints for your wrenches. Those were the things that helped me out...

 

khendrix has it mostly right, you need to loosen the plugs 1/8th of a turn and then spray the Kroil in the spark plug well. If you don't loosen it hows the oil going to penetrate the carbon?
And a warm engine does make a big difference.

 

I did not loosen my plugs at all.

I removed all my plugs at about 30k... or so just to check them.

I sprayed all the holes without loosening the plugs at all. Came back a couple hours later and emoved the plugs easily. The penetrating oil WILL penetrate. Neither time did I losen the plugs first before spraying... that's what the spray is for.

I say spray the plugs first.. let them soak.. then come back and turn each plugs just barely.. then add just another small spray again. Fool proof then.

 

Just had mine replaced at dealership a month ago, at 29k, since there have been many posts about guys having problems with the removal. I kept the old ones, they marked which cylinder each came from and put the used ones back in the new box. Was curious to see how bad they were, since I ran my truck pig rich for about 5 months before MT adjusted the AF's during some dyno time I had with him in Feb. I was surprised, they looked a bit fried for only 30k. Mechanic did the plugs in about 15 minutes, I have an 06 and they just came right out, not sure of the prep work they did on them but plugs and fuel injector cleaning and I was out of there in about 1 hour.

 

Thanks for the replies guys. Really, I feel a little better about the plugs. I'm thinking I'll remove one and see how it goes. Do I need to replace the plugs at 30k or so, or just clean and put back in with some neverseize? Being my truck is an 05, I hate knowing that there is the possibility of them seizing if I wait until 100k miles before changeout. B/c many/most 5.4 3v trucks haven't reached the 100k mile range yet, many of us are hanging on, wondering if it's wise to wait or to start inspecting them early. The reason I vented about the Dealerships is b/c they flat out deny there is even a condition to consider. That chaps my butt something serious. They say, "never heard of a problem, wait until 100k". I love this truck otherwise. Has given me 33k trouble-free miles so far. Couldn't say that about my 2003 GMC Z71 POS.

 

Is anyone really sure how long this anti-seize will last if applied to the plugs? Is this something that will last 30k, 50k 75K? In other words, does it need to be reapplied every so often or will it last until it is really time to change the plugs?

 

The key here is only 30K. You shouldn't have any trouble getting them out of a warm engine at that mileage.
With the plugs tight the penetrating oil WILL NOT be able to get past the seat where the plug seals to the head. If it can't get by the seat it can't get down to where it's needed, The Ground Shield!

 

This is like talking to many dealers about how bac 6.0 Power Stroke Diesels are. Many dealers truly have not experienced the problems that some of us have. And while all this free info we get from members on sites like this would seem like an obvious place for the folks at the dealerships to know about, they don't.

I had my 07 in for service last week and asked the shop foreman about the plug issue. He looked at me like I had 3 heads, then went on to explain Ford corrected the plug issues that he'd seen on the Triton 2V's. My first reaction was like yours, he's full of it. But after talking with this guy for a while, it became clear that I had more info about this stuff then he.

So, just suggesting that sometimes we jump to the wrong conclusion with respect to stealership personnel. Some honestly don't know.

Just a thought.

 

It's sad when that happens. When I bought my first new car when I was 21 I knew more about the car than the senior salesman that sold it to me. (This was LONG before the internet age began) I think I should have charged him for the lesson.

 

I totally disagree. I fully believe penetrating oil WILL and DOES seep past the "seat".

If you spray fluid down in a hole and wait 24 hours.. I would bet money the fluid will not be visable the next day.. and the plug will slide out fine.

I was a disbeliever myself saying " Spraying the hole will make no difference because the sleeve is the part that sticks, not the threads!" By george, the oil seeps past the threads and onto the sleeve.

 

That must be some special penetrating oil you are using if it can seep past the seat when the plug is still tight. The seat that is there to keep compression in.
And I didn't say the penetrating oil wouldn't seep into the area that it needs to (The ground shield/sleeve) The plug needs to be loosened 1/8 of a turn to allow this.

 

That's what I don't understand. If the plugs are going to break off, I would think they would snap as soon as you start to loosen them. How can they come out an 1/8th of a turn and not snap? If the oil doesn't work until the plugs are "cracked", how can it be effective at all. It's not the threads but rather the shield that gets stuck, right? If so, how is the oil effective?

 

Same here in Colorado. I'm coming up to my 30k service, and five out of five Ford dealerships told me that they have never heard of this problem, and told me to wait until 100k. I'm not going to risk it; at 30k my plugs will be replaced.