Spark Plug Removal NIGHTMARE!
I know what you are going thru right now. After reading all the posts on here I took mine to the dealer and had them do it. They broke one & my truck was down for a week almost. The dealer ate the bill but it was nerve racking just waiting. Are you replacing the plugs with oem or going aftermarket ?
Thanks so much for everyones support.
I will keep everyone informed on it... cost and all.
The plugs are the same, just a heat range down.... I am not sure what else to put in there.
What I am sure of though is I will never mess with these spark plugs again....ever!
I would rather take a direct kick to the jimmy then fool with these BS plugs.

I will keep everyone informed on it... cost and all.
The plugs are the same, just a heat range down.... I am not sure what else to put in there.
What I am sure of though is I will never mess with these spark plugs again....ever!
I would rather take a direct kick to the jimmy then fool with these BS plugs.
Last edited by ford2004F150; Nov 14, 2008 at 09:00 PM. Reason: spelling
3 of mine broke when my friend changed them and the last two were the rear ones. They ended up using some kind of chisel tool and a hammer and just breaking them into pieces and then using a vacuum on one and another tool they put together to get the remainder of the plugs out.
What a **** design.
What a **** design.
You don't need a head job. Just get the tool from Matco. It works great, both for the porcelain and the bottom piece. and ALOT cheaper then a head job.


I did a post about this ill find it for you.


I did a post about this ill find it for you.
Here.....https://www.f150online.com/forums/20...-pictures.html
3 out of 8 Broke. I removed all and installed all in under 2 hrs. Specialty tools are the best.
3 out of 8 Broke. I removed all and installed all in under 2 hrs. Specialty tools are the best.
Last edited by milkthegoat; Nov 15, 2008 at 10:16 AM.
Thanks so much for everyones support.
I will keep everyone informed on it... cost and all.
The plugs are the same, just a heat range down.... I am not sure what else to put in there.
What I am sure of though is I will never mess with these spark plugs again....ever!
I would rather take a direct kick to the jimmy then fool with these BS plugs.

I will keep everyone informed on it... cost and all.
The plugs are the same, just a heat range down.... I am not sure what else to put in there.
What I am sure of though is I will never mess with these spark plugs again....ever!
I would rather take a direct kick to the jimmy then fool with these BS plugs.
Yes, the truck is back at the house.
They got them out without pulling the head but it wasn't easy.
Nor was it cheap.
Here is the breakdown.
Tow 2 x $90 = $180
Labor for 2 plugs = $480
TOTAL = $660
So $660 to change two broke sparkplugs.... this was an EPIC FAIL on FORD's design of this part.
This is the kind of stuff that turns consumers away from FORD.
This is the kind of thing I will remember when purchasing my next truck.
I've always been loyal to Ford, but this is chipping away at that loyalty.
They got them out without pulling the head but it wasn't easy.
Nor was it cheap.
Here is the breakdown.
Tow 2 x $90 = $180
Labor for 2 plugs = $480
TOTAL = $660

So $660 to change two broke sparkplugs.... this was an EPIC FAIL on FORD's design of this part.
This is the kind of stuff that turns consumers away from FORD.
This is the kind of thing I will remember when purchasing my next truck.
I've always been loyal to Ford, but this is chipping away at that loyalty.
anyone have success with the lisle tool?

I can't afford to have the truck sit, so I figured I'd buy the broken plug remover before I snap them off...
I'll get the matco plug socket as well, but I can't find the remover on their site. Anyone have a link?
I remember seeing something about a 1 piece plug being available, but can't remember which brand. Do they make a 1 piece platinum plug?
I can't afford to have the truck sit, so I figured I'd buy the broken plug remover before I snap them off...
I'll get the matco plug socket as well, but I can't find the remover on their site. Anyone have a link?
I remember seeing something about a 1 piece plug being available, but can't remember which brand. Do they make a 1 piece platinum plug?
Champion 7989 is a double platinum one-piece plug. The Champion plug uses a 5/8" socket and not the 9/16" that the Motorcraft plugs take. Matco makes a couple different spark plug extractor tools that are much less expensive than the Ford Rotunda tool.
Link to Matco tools catalog page: http://www.matcotools.com/Catalog/to...at=2195&page=6
Link to Matco tools catalog page: http://www.matcotools.com/Catalog/to...at=2195&page=6
Last edited by kd4crs; Nov 18, 2008 at 05:44 PM.
Champion 7989 is a double platinum one-piece plug. The Champion plug uses a 5/8" socket and not the 9/16" that the Motorcraft plugs take. Matco makes a couple different spark plug extractor tools that are much less expensive than the Ford Rotunda tool.
Link to Matco tools catalog page: http://www.matcotools.com/Catalog/to...at=2195&page=6
Link to Matco tools catalog page: http://www.matcotools.com/Catalog/to...at=2195&page=6
wish me luck...
I read everything there was to read about it, bought everything I needed, took a deep breath, and jumped under the hood...and after all that my truck is sleeping at a machine shop tonight!!!
I got a couple out with some trouble, but the 3rd one I tried to pull snapped off. "No big deal, I've got the lisle puller right here". goddamn it. The way this one broke left some porcelain above the tip so when I used the plunger part of the lisle kit, it must have pushed the tip further down into the head cause the extractor screw couldn't reach enough metal to bite into it. Now what? had to call around to see who knew about this problem and found a very capable shop. I have no idea what it's going to cost me yet though. The only thing saving my sanity right now is the fact that they seem to be real pros. For the first time in a long time, I don't question the ability of the guys working on my vehicle.(lets just say I've paid very good money to a few undeserving "mechanics")
I'm a mason by trade, so no pro mechanic by any means, but I've worked on my own vehicles doing brake jobs, front end work, tune ups etc... for years and have never once had to call a tow truck or garage to fix something that I was working on! Ford has made me feel like less of a man today. For this I will not buy another ford truck...well not anytime soon anyway. I do still love my big dumb 7 cylinder 5.4
I'm just posting this to let people know that even though I was fairly confident in my ability, once the extractor didn't work, I had to call it quits before it got any worse. I broke one of the old plugs open afterward to see if the tool would work. It grabs really tight, but the porcelain has to break off in the right place for it to work. I guess that turned the job into a game of friggen roulette.
-1 pissed-off truck owner
cheers!
I got a couple out with some trouble, but the 3rd one I tried to pull snapped off. "No big deal, I've got the lisle puller right here". goddamn it. The way this one broke left some porcelain above the tip so when I used the plunger part of the lisle kit, it must have pushed the tip further down into the head cause the extractor screw couldn't reach enough metal to bite into it. Now what? had to call around to see who knew about this problem and found a very capable shop. I have no idea what it's going to cost me yet though. The only thing saving my sanity right now is the fact that they seem to be real pros. For the first time in a long time, I don't question the ability of the guys working on my vehicle.(lets just say I've paid very good money to a few undeserving "mechanics")
I'm a mason by trade, so no pro mechanic by any means, but I've worked on my own vehicles doing brake jobs, front end work, tune ups etc... for years and have never once had to call a tow truck or garage to fix something that I was working on! Ford has made me feel like less of a man today. For this I will not buy another ford truck...well not anytime soon anyway. I do still love my big dumb 7 cylinder 5.4
I'm just posting this to let people know that even though I was fairly confident in my ability, once the extractor didn't work, I had to call it quits before it got any worse. I broke one of the old plugs open afterward to see if the tool would work. It grabs really tight, but the porcelain has to break off in the right place for it to work. I guess that turned the job into a game of friggen roulette.
-1 pissed-off truck owner
cheers!
I read everything there was to read about it, bought everything I needed, took a deep breath, and jumped under the hood...and after all that my truck is sleeping at a machine shop tonight!!!
I got a couple out with some trouble, but the 3rd one I tried to pull snapped off. "No big deal, I've got the lisle puller right here". goddamn it. The way this one broke left some porcelain above the tip so when I used the plunger part of the lisle kit, it must have pushed the tip further down into the head cause the extractor screw couldn't reach enough metal to bite into it. Now what? had to call around to see who knew about this problem and found a very capable shop. I have no idea what it's going to cost me yet though. The only thing saving my sanity right now is the fact that they seem to be real pros. For the first time in a long time, I don't question the ability of the guys working on my vehicle.(lets just say I've paid very good money to a few undeserving "mechanics")
I'm a mason by trade, so no pro mechanic by any means, but I've worked on my own vehicles doing brake jobs, front end work, tune ups etc... for years and have never once had to call a tow truck or garage to fix something that I was working on! Ford has made me feel like less of a man today. For this I will not buy another ford truck...well not anytime soon anyway. I do still love my big dumb 7 cylinder 5.4
I'm just posting this to let people know that even though I was fairly confident in my ability, once the extractor didn't work, I had to call it quits before it got any worse. I broke one of the old plugs open afterward to see if the tool would work. It grabs really tight, but the porcelain has to break off in the right place for it to work. I guess that turned the job into a game of friggen roulette.
-1 pissed-off truck owner
cheers!
I got a couple out with some trouble, but the 3rd one I tried to pull snapped off. "No big deal, I've got the lisle puller right here". goddamn it. The way this one broke left some porcelain above the tip so when I used the plunger part of the lisle kit, it must have pushed the tip further down into the head cause the extractor screw couldn't reach enough metal to bite into it. Now what? had to call around to see who knew about this problem and found a very capable shop. I have no idea what it's going to cost me yet though. The only thing saving my sanity right now is the fact that they seem to be real pros. For the first time in a long time, I don't question the ability of the guys working on my vehicle.(lets just say I've paid very good money to a few undeserving "mechanics")
I'm a mason by trade, so no pro mechanic by any means, but I've worked on my own vehicles doing brake jobs, front end work, tune ups etc... for years and have never once had to call a tow truck or garage to fix something that I was working on! Ford has made me feel like less of a man today. For this I will not buy another ford truck...well not anytime soon anyway. I do still love my big dumb 7 cylinder 5.4
I'm just posting this to let people know that even though I was fairly confident in my ability, once the extractor didn't work, I had to call it quits before it got any worse. I broke one of the old plugs open afterward to see if the tool would work. It grabs really tight, but the porcelain has to break off in the right place for it to work. I guess that turned the job into a game of friggen roulette.
-1 pissed-off truck owner
cheers!
That sucks my friend! I am thinking about doing this myself but I may just pay the dealership to do mine. I like to think to myself that I am fully capable of changing a spark plug but thanks to those highly intelligent Ford engineers they have put some doubt in my mind. That doubt may just put $249 in my local dealerships pocket "IF" the plugs come out in one piece!
Thanks Ford--I hope when you guys are begging for money to bail your a$$e$ out of a financial crisis you get the same answer we get when we ask you guys to help us out with the spark plug crisis which is "Sorry your SOL!"


