Hi guys,

This is a great forum that you've got here. I'm having a bit of a problem. I just bought an 05 F-150 with 90k on it about a week and a half ago. Since I had been reading on here prior to purchasing, I negotiated that a tune up and plug change be included in my deal at no cost to me. They agreed. As of today, the truck is still sitting in their shop. When they went to change the plugs, they broke off "4 or 5 of em" as I was told. Apparently they were required to remove the heads to get them out. Each day I get told that "It will be ready tomorrow, you can come and pick it up in the morning." only to call the next morning and get told the same thing. I also understand that there is a TSB about this and that it is very rare for them to have to remove heads at this point to get them out.

So, my question is, how long should this take them to repair. I need this truck. A week and a half in the shop seems excessive to me, even if they had to remove the heads. Maybe I'm wrong, but I figured that you guys would know better than me. Thanks in advance guys.

 

havent had mine done yet dreading the day but my understanding is they have a tool now to get them out without removing heads sound like they are giving you the run around because your not directly paying for the work so they just shove it to the side. just my .02 cents

 

Is a dealer doing the work? If so they should have it done the same day. The techs have the tools to get the broken bits out without pulling the heads.

 

That was my thought as well. I just wanted to make sure my thinking wasn't wrong since I'm not nearly as familiar with these trucks as I am others.

Yes, a dealer is doing this work, a rather large one at that. They have already pulled both heads. I know that it has at the very least been in the shop since Friday (4 days ago when I went in to pick it up and saw that it was on the lift still), and they say that it has been in there since I signed the papers (a week and a half ago).

 

Im thinking its not the dealer or they would know how to removel them. (One would hope!) Im just guessing you bought it from a auto car lot that probably wasnt aware of the issue and didnt know of the tool to get to remove them?

 

If they had to pull the heads, they don't know what they are doing. There are special removal tools and each broken plug should add 30 minutes or so to the job. It sounds as if they totally ignored the TSB for plug removal. If followed, rarely does one break and when it does, it is not a big deal to get it out.

 

That was my fear. Does anyone have a link to the TSB on this? I would love to have that in hand when I talk to them next. Thank you.

 

Wow, that's pretty sorry. There are regular joe's on here that have made plug removal tools out of items in their garage and your dealer has to remove the heads to get the broken plugs out? I wouldn't get let that dealer anywhere near my vehicle.

 

Thats just crazy and thought my FORD dealers were morons!! Atleast you did your homework and made them change them. I wouldnt blame you if you told them nevermind and looked else were. Its a freaking joke FORD didnt do anything about these trucks and these plugs!! A simple plug change anyone could normally change. Just think if you bought that truck and took it to them 4 months later and they broke the plugs and had to pull the heads cause they broke 4 of 8. You would think the dealer would have to pay but heard the owner had to cover that charge too? It would cost you $400.00+ to pay for a plug changed. I love my truck but really ticks me off on this plug thing!!

 

http://ww2.justanswer.com/uploads/jm...sb08-07-06.pdf

 

TSB 08-7-6

04/14/08

SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L
3V/5.4L 3V16.8L 3V

FORD:
2005-2008 Mustang
2004-2008 F-150
2005-2008 Expedition, F-Super Duty
2006-2008 Explorer,
F-53 Motorhome Chassis
2007-2008 Explorer Sport Trac

LINCOLN:
2005-2008 Navigator
2006-2008 Mark LT

MERCURY:
2006-2008 Mountaineer

This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List.

ISSUE
Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.

ACTION
Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs.

SERVICE PROCEDURE

The engine build date can be read on the left hand cam cover information sticker.

To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted.

CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED.

Spark Plug Removal Procedure

1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air.

2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point.

NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.

CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.

CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS.

3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs.








NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure

A couple of tips-
The truck needs to be completely cold, meaning it must sit for at least 8 hours before starting to do the work.

Use the Motorcraft Carb cleaner, it works better than anything out there to melt the carbon.

Make an adapter for your shop vac so you can suck any carb cleaner or debris from the cylinder out the spark plug hole. I got a pcv reducer from the harware store and step it down to a hose I can put in the clyinder

Change your oil after changing plugs to remove any carb cleaner that gets past the rings.

 

It's really no big deal if you follow the TSB. Many members have pulled them themselves with success.

 

That's a good link, Stealth. Shows the removal tool for broken ones. Use the Lisle tool.

 

That is just sad. I agree with jjntj2003, since your not paying the bill they just keep pushing it to the side and only working on it when there's a spare minute.

 

I copied the link recently and saved it in my documents as well. I may get brave one day.