Well, I followed the TSB, soaked the hell out of the plugs, and turned on them slowly for the better part of 6 hours and two still broke.

Both have porcelain left, no electrodes, and pretty much broken off flush.

Will the Lisler tool do the job? Or am I looking at head removal?

 

Advanced title search lisle tool and you'll get the info you need.

 

Well, whether it will work or not seems to be up in the air. From the posts it looks to be around 95% effective.

I ordered the Lisle tool, so it should be here in a few days.

From my experience thus far it seems that the supercharger companies need to really include a "complete" kit out of the box ready to go.

I mean, ship this back to us and then, we ship it back to you with plugs is BS. No matter how you do it, the truck is going to sit for a week or more just from the lack of a PCM.

It would be nice to have a "roots" style kit with plugs, programmer, and all equipment to the door ready for install.

Anyway, the plug issue would have happened regardless. What a mess on this plug design, I tell ya.

 

First thing I did was mail the PCM to Roush in their pre-paid next day mailer. They had it back to me before I was finished with my install. Sent it Thursday afternoon, got it back Monday morning. Even though I had the new plugs, I only had 8,000 miles on the engine. Can't blame Roush for Ford's plug design.

 

Yes, but the Roush manual states that 2007 and earlier will require colder plugs. 2008 and after use stock plugs. Roush knew before hand that my model would need plugs cause I told them it was a 2004 model.

I know they are quick on the return, but installing the plugs after the blower is on is harder. It would be MUCH easier to change the plugs while the manifold is off and everything is broken down.

Hopefully, the extractor tool gets here quickly. I asked for expedited shipping. On top of that...I hope it WORKS!!

 

Oreilly auto parts has the tool and you can get it in a day usually. Heck my store in Hempstead stocks one. I made my own puller for less than 5 bucks to extract my broken plug.


Just use a small long screwdriver to chip at the porcelin and a shop vac to suck out the small pieces. Some had also mentioned about turning the motor over to allow the compression to blow the porcelin out. Just sit back, drink a beer and think it through.

 

Well, the woman had her car at work and I wasnt' going to walk 5 miles to the nearest parts store I did make an attempt to make my own tool, but I was short of either the right thread, nut, or length in order to do it from my spare parts tray. I was pretty close to what you used by emptying the shell of another existing spark plug, cutting off some material, and tapping and threading a bolt inside of it. It worked okay and pushed the porcelain down a little bit, but I ran out of length and not enough bite to tap into the plug.

So, I bought the tool cause I called everywhere in town and nobody had ANY idea what I was talking about. They were literally lost. It might e better to have the tool anyway.

Thanks for the help and BTW, the PCM is on it's way back to me now.

 

i'm wondering what is breaking on the spark plugs anyone have pics of a broken one... i'm confused and curious never dealt with this (2v guy here) i'm just curious.

 

Both plugs are out!! Lisle Tool worked great.

BUT, one of the plugs had a piece of porcelain crack at the ground strap and fall into the cylinder...it coundnt have went anywhere else. The piece is about the size of a piece of rice. I vacuumed the cylinder and looked in there with some light and saw nothing. But, there is no porcelain piece in the vacuum that can match or resemble the broken piece.

Will this piece make its way out of the exhaust chamber or is it a problem?

 

It will eventually break apart and end up in the exhaust. It could do some minor pitting on the head, but not enough to hurt anything. The ideal thing to do is get it out if possible, but if not, you don't need to pull the head.

 

Not sure if you tried this or not but you can make a small adapter and put it on the end of your vaccum that will fit throught the spark plug hole and try that way.

 

They even make adapters for vacuums that are used to clean computer keyboards, etc.

http://www.amazon.com/Schneider-Indu...9140425&sr=8-7

This would probably work fine.

Lee

 

How many miles on the plugs when you tried to change them out? I've yet to run into any problems in a boosted application, I change out at 20,000 miles.

 

Mine had 50k on them and mine can out ok but i turn them out a little and then back in then back out just like you would if you were tapping a hole.

 

I use Kroil to soak them down overnight, then I use the recommended Motorcraft procedure the next day. Has worked like a charm for me. Not even a squeal or anything which make me nervous taking them out.