After nearly 7 years and 127k miles we are finally tackling the plugs on my '04 5.4 3v.

I have to laugh to keep my composure. After reading tons of threads on this task I knew what I was possibly up against. Luckily my cousin is a mechanic and has done this many times before.
So, he has the expensive extractor tools for when the plugs break off in the heads.

It still took us 5 hours to replace the two front plugs. LOL We followed the directions on the TSB's word for word. "Didn't help"
The plugs instantly broke off in the head and didn't even try to come out. The exposed plug half simply unscrewed out and left the inner half behind. The inner part was completely rusty and corroded and pretty much glued to the head.

Gonna tackle two more this weekend. My cousin thinks that it might be quicker and easier at this point to just remove the heads and replace the rest on a bench.

Oh well, I figure I had it coming since I waited so long to do it.

Can hardly wait.

 

Others have gone longer than that and got them out. Are you letting them soak for hours before you break them loose? Then after breaking about 1/4 turn, soak again for 30 minutes or so? before doing the back and forth workout? The initial soaking works best with Kroil and then use carb cleaner to loosen the carbon.

 

Believe it or not they soaked over night. I'm thinking we didn't break them loose enough to soak in. Not sure what product my cous used on them. I'll find out. I'll make sure we break them loose and soak them real good this time.

The worst part is the truck still runs like new and gets decent mpg's. Thats why I waited this long. I'm only doing it now because everyone says it needs to be done.
The electrodes on the old plugs looked almost as good as the new ones. Seems like alot of effort for nothing.

 

When you go and take the rest of the plugs out this weekend, try it with the engine warm, I've done a few this way now and none have broke, whereas when i used the TSB at first i was breaking lots.

 

Yep, difficult to pull the trigger when they are running good. If the electrodes are worn down much it makes the coils work a lot harder and they will start to fail. Probably a good idea to go ahead and get them done.

 

Its a joke FORD screwed up these trucks on the plugs this bad. Honesly if I would of known this before I bought my truck I would of never bought but 05 truck. My previous FORD 98 truck I could replace all the plugs in an hour.

Luckly I had an issue with my truck under the extended warranty and replaced all my plugs at 50K for free and now have 60K so I should be good go for a couple of years I hope. Good Luck with the rest of the plugs!!

 

Thanks for the pointers guys. I'll warm it up this time too.

The ones in the back are really gonna be a pain if they break.

 

So you would have bought a completely different vehicle just becuase of a issue that should come up probably 2 times the entire time you own the truck?

Wow.

 

I would have. I have a low B.S. intolerance threshold. Fortunately, the engine in my screw was made in May of '08 and the plug boots are brown so I shouldn't have to worry about it. Still, four years to fix the problem? Come on, Ford!

 

It's not just the plugs - the cam phasers have been an issue too, along with the 05 injectors. I'd never buy an 04-08 5.4.

 

Taking mine to dealer tomorrow for plugs. Have 59K on mine, I run a can of BG44K thru mine every six months so that should help and I run it at max rpm from time to time. Dealer charges $300 bucks out the door. No charge for broken plugs ( they said they haven't had any broken plugs for a cpl months).

No ordering plugs, no scraped knuckles, No ordering lisle tool, no hrs leaning over fender on a step stool, drop it off at 8am pick up at 4pm, Mastercard, gotta love it.

 

You soaked them, but with what? There is an old TSB and a newer one, with the newer one explaining to use MC carb cleaner for the soak. Do not use anything else.

 

Plugs can be changed without breaking.

Cam phasers make noise, which is a non issue unless you like an engine that makes no noise, and none exist.

07M08 solves this problem.

No worries here.

 

I have heard stories of common problems with these trucks as mentioned above from many of you and on other forums.

Truthfully this has been the best truck that I've ever owned. 127k miles and not one issue whatsoever. I've hauled my Mustangs all over the country and other trailers. Its a trusty daily driver and not a bad tow vehicle either.

I'm 46 years old and I've had many."all brands" I think this has been a good truck.

Once I get past this sparkplug project I'll be happy again.

I agree that Ford engineers should have thought this one through a little more. A man should be able to change his sparkplugs without these type issues. LOL

 

Im not looking foreward to change mine, i got 90,500 miles on my 04 5.4. Still seems to be running good, but I bet as soon as I post this she will start to run like hell. Cam phaser noise, but its all good. I love my truck, shes worth the time and money.