1997 F150 XLT, went into the dealership to change plugs, wires, basic service and to my dismay they are reporting #4 plug is stuck in the head!

I'm trying to see what options I have before I go in to them in the morning. They are recommending replacing the head for $2300USD.

I need some advice as to how to move forward. The vehicle is driving but its missing badly and hesitating badly if too much throttle is applied during acceleration.

Thanks for your input.

 

How many miles are on those plugs?

If it were me, I would have them replace the 7 other plugs, then give the truck back to me. Then I'd take it home and try like heck to get that plug out without removing the heads (as that's a quite expensive & involved task). There's a TSB for removing plugs from the newer 3-valve 5.4 motors. I know you don't have that motor, but you could still try the method.

Basically, you want the motor to be warm, not hot and not cold. Try to unscrew the plug no more than 1/8 turn. Then saturate the plug are with some penetrating oil (Kryoil, PBlaster, etc). Spray enough to cover up the jam nut. Then let it sit for a while, maybe an hour or so. Go back out and try to work the plug back & forth, in 1/4 turn, out 1/2 turn, in 1/4 turn, out 1/2 turn, and so on... If need be, continue applying the lube. Just be sure you don't use TOO MUCH, as it could hydrolock your cylinder (although it would take ALOT of spray to do that). With any luck, the lubricant will free the plug, and you'll save yourself lots of $$$.

 

Also, #4 plug is all the way in the back on the passenger's side. That's the toughest one to get to. So be prepared to possible remove some other components to get to it. For my truck, the PCM needs to come off for easier access. Yours could be similiar... or not...

 

The plug /head threads are probably galled and are preventing the plug from being removed. If it was me I would try and force the plug out which means the threads will more than likely be shot in the cyl head. Then repair the plug hole with a Heli-coil. I am a little puzzled why the engine is running rough just because they couldn't get the plug out. They must have damaged it pretty bad in their attempt to remove it. Also since the truck I assume was running fine before the dealer messed it up I would insist that they pay for a fair portion of the repair if it comes to that. I think $2,300 is high. A cyl head can be purchased on E bay for around $300.00. By the way your head is prepower improved and I have changed these modular heads just working in my garage in a day. So it is a repair the average person with some mechanical ability can perform. Good luck.

 

BAMORRIS:

Thanks for your reply! I am in the Bahamas, so I think thats why the price is soo high to begin with, secondly their the only FORD dealer here. I have tried this past weekend to get it out myself with a friend who is an aircraft mechanic (A&P) with penetrating oil but to no avail.

I will go the route you suggested and remove the vehicle from the dealer with the busted plug and attempt to seek assistance somewhere else, perhaps from a bush (shadetree) mechanic.

I spoke with someone tonite locally who said a "TAP and DIE" job on the head could possibly a solution if they have to "BREAK OUT" the stuck plug. Well, I'll get the truck tomorrow and report on whats what.

Rgds,

 

I am about to attempt to pull my head on my 98 F-150 w/ 4.6
I think I will put an insert in it. 230,000 mi, but truck ran great before dealer did a compression check. 3 days later plug comes flying out of head. They put it back in, no insert. Now they won't help with any costs even though they are the ones that *******ed up my head.
Time Sert looks good. I am going to try to pull head tomorrow. Any advice is appreciated. How do I get the fuel rails disconnected from the lines?
TK