The other day while cruising at 50-55mph, I stepped on the gas and my truck began to shudder violently, especially at lower RPMs. I took it to the nearest dealer and they told me that the metal sleeve above the electrode on one of my plugs had came off and fallen into the cylinder. They were unable to investigate with the Borescope because I was told that the sleeve had been forced up into the head and was blocking the hole. The vehicle has 88,000 miles on it and the aftermarket warranty I purchased is good for 5 yrs, 100,000 miles. The warranty company (Continuous Customer Care) isn't going to cover ANY of the repairs since it was the plug that failed, and that isn't a covered component. Ford motor company is only offering to pay UP TO 30% of the repair bill which could be as low as $1500 or as much as a new engine. Since they can't investigate with the borescope, my dealer is offering to break down the motor to investigate the damage this has caused which is going to cost me +/- $1000 in labor. Has anybody heard of this happening before? All of the spark plug issues I've read about were the plug actually being ejected from the head, but no metion of this. Is there anything in the cylinder that could strike the plug and cause this damage? I'm in a terrible position here, and feel like someone should step up to the plate (Ford, the warranty company, my dealer) and help me with this repair, but nobody has. Any advice for a frustrated Ford owner?

 

Hi.

sucks.

You bet these things are a problem - there are literaly hundreds of posts on the 3V plugs - here's a couple:

https://www.f150online.com/forums/sh...ht=spark+plugs

https://www.f150online.com/forums/sh...ht=spark+plugs

https://www.f150online.com/forums/sh...ht=spark+plugs


You failure is a bit atypical - as most that have had problems, the sleeve was retained in the head. The only time stuff fell in was when removal ( usually not following the TSB) was attempted.

Read, read, read. And view the video in Stealth's sig.

In your case, looks like head removal will be required.

Be a squeeky wheel. Also understand that these plugs are best not left in that long....

Good luck with reimbursement - I sincerely hope your engine did not get damaged too much.

 

I can't see how it could fall inside the cylinder unless it shattered..BUT , how would that happen ??? Got me on that one..

 

Heck of a first post. Hmmm.

 

http://www.blownoutsparkplug.com/

 

Here's a pic from masterd's post awhile back

2004 plugs and newer, as you can see they are different from your normal old plugs.

 

Okay , I see how they can break and fall in - Glad I don't have to run those..

 

Hi.

That's just it - that sleeve you see is the very part that's binding in the bore - carbon deposits wedge it so badly that unless a specific extraction method is followed the dang thing just stays in there, while the centre electrode, ceramic and the rest upper part come out.

In this case it fell in apparently on it's own - interesting and somewhat troubling, because this failure mode I haven't seen being reported anywhere. Until now.

 

I have bookmarked this site. Thanks for the heads up!!

 

Stealh There was a post by one of the members when he did plug change He could turn the bottom of the plug I think it was Jalapiono that did this He posted a video I can see a shield breaking off and fall into the cylinder by his video of the spark plug removed and showing how it spins

 

Hard to comment on this - the plugs didn't look like that here - they were normal looking . We did an 04 and an 05 model - both 5.4L's and the plugs that came out were not like the ones in that picture - I wish I had taken a picture.

NGK's went in the 04 and Denso's in the 05 - or visa versa , i can't recall, that was almost a year ago.. But they looked like a normal plug - NO insulators like that picture ..

 

WTF?

Buddy - ALL the 04+ trucks with 5.4's are 3v's with the new plug design - and until recently ONLY Motorcraft or Autolite made the plugs. Now Brisk is in the market, bur Denso and NGK still do not make any plugs for these motors.

And a conventional plug simply will not fit - even if it did, the depth of that bore would shroud the plug so much it would not even run right if at all.

You sure they were not 4.6's?

 

9/16 - check out the NGK site - theres like 5 different types

 

Nope - the 04 Heritage 5.4 uses a TR6 - it's a 2V plug, 2V flex fuel motor

I looked @05's, 06's and up - no 5.4's listed at all.

You into the sauce?

Yer gonna have a hard time convincing me

 

I'll take pics next get together - oh crap , I'm not going to be here on turkey day ..