Hey guys, thought I'd share my story and how I successfully changed the spark plugs in my 04-F-150 with 95XXX miles on it. I am the original owner and am absolutely positive that this is the first time these plugs have been out. I do all my own maintenance and always have.

Ok, now that that's out of the way. Here's how I went about it and how it worked.
At 90,000 miles I pulled the COP's, tried to turn out the plugs and gave up (none moved). Sprayed in a good deal of aero-kroil left overnight, and reinstalled COP's.
Drove truck another 3,000 miles and pulled the COP's again, tried to turn out plugs, and all but one (back left) turned about 1/4 turn. Not easy however. Sprayed in some more AK and left overnight. Next morning, turned plugs back and reinstalled COP's.
2,000 miles later *95000 miles* I removed COP's, Computer, Computer mounting plate and removed all plugs successfully with MUCH LESS torque than before and finally managed to turn the back left plug a quarter turn. Sprayed in more AEROKROIL and let it sit a few hours and was able to turn it out all the way. All plugs replaced, no breakage, just A LOT of extra labor.

Had I done the TSB I'd have broken plugs FOR SURE. If you got the time and patience (and AeroKroil) you can drastically increase your chances of success.

Have fun.

Jarrett

 

sweet thanks I am coming up on the time to do this. I think I will try this I would much rather be patient and have no breaks.

 

I'm glad you got it to work, esp with that many miles. I'm still curious as to whether the aerokroil does anything for plugs that haven't been loosened that 1/4 turn. Until the seal/seat is broken, I don't see the aerokroil doing anything to help with the initial 1/4 turn. If most breaks occur during this first 1/4-1/8 of a turn, spraying a bunch of penetrant in a plug well, reinstalling the COPs and driving wouldn't make one think it will have any effect on helping to loosen the plugs. I not trying to say you're wrong, b/c Ford can't seem to get it right and they've had 4 years to work on it. I thing somehow getting a penetrant/carbon dissolver to the sheild area before attempting to break the plug loose is the key. Maybe a top engine decarbon or something of that nature is what Ford should be trying to work on to help. They've tried enough with after the fact methods that's for sure. Just look at the TSBs and how they've change concerning this.

 

When you sprayed the AK in at 90K, did it seep down into the cylinder, or just stay in the well?? You said you reinstalled the COPS and drove for another 3K. I would think this would be a HUGE fire hazard if the AK just stayed in the plug well. Aren't the COPS firing like 60,000 volts??? Isn't Aerokroil flamable??

 

You hit the nail on the head. If that darn stuff can seep past a tightened plug seat then, da-n, I'm getting me some of that. Othewise, I would think flamable fluid + high electric discharge= Kabooooooooooom!!!!

 

According to the Kanolabs website, the stuff can penetrate to 1 millionth of an inch.

 

I did leave the AK in there overnight and waited to install the COPS till I blew out the spark plug wells with compressed air. However, I had no problems with any flame hazard. I'm not claiming to have some fool proof plan to get out the plugs, I'm just sharing what I did that worked. I think the key is to take your time and if your lucky enough to get that initial turn, you will probably be successful.

To be clear, there was NO standing AK in the plug well. That's definetly not a great idea.

 

I read here recently somebody using an impact wrench(don't know if air or electric) to get the initial 1/4 turn. He got all out without breakage or damage. It scared me when I first read this but it makes some sense. If an impact wrench can give a little hit as pressure is applied to the jamnut, it might break free easier than by just using a manual socket wrench. I wouldn't use an impact wrench after the initial breaking of the seal but it might just work for the initial 1/4 turn.
P.S. I'm not trying to hijack the thread. Just adding this to what's been done here since this is new as well.

 

Was at NAPA today and talked with the clerk. He said they had a guy come in and buy 8 spark plugs for an 04-F150 and changed them in the parking lot. He said the guy had one plug that backed almost all the way out and separated from the ground shield so the two pieces where spinning independently. He said the guy tried to put everything back together and drive it to the ford dealer, the compression stripped the threads in the head and ejected the spark plug.
All I did was mention how damn expensive the plugs are.

 

I am doing this now,I cant imagine a $89.95 tune up on these motors,This job is a PItA.Hope to finish tommorow.I had to go to a colder heat range on my 08 car that has a 5.4-But it has 4 valves and uses normal plugs-Only took about 20 minutes.

 

never heard of a 5.4 with 4 valves...........

 

I will give a hint,It is not naturally aspirated and has snakes on each side.

 

GT500 Supersnake?

 

Just a plain GT-500 with some mods,Adding the KR hood as soon as I paint it.Back to the spark plug thing-The lower half remains in the head on the right rear.This is not gonna be a cake walk!!! If it could have just been closer to the front.I guess all I can say is dammit!!!