Hi, I'm new here and looking at buying a used F-150. However, the reports of spark plug problems are numerous and I'm having trouble getting my facts straight regarding the 5.4.

As I understand it, the spark plug blowout was resolved with the '03 model, but in '04 a new problem with the plugs breaking when removing them became an issue, which in turn was fixed in '08.

I'm looking for clarification that what I have gathered is correct, and also what the fix is for the plug breaking problem. Is it simply a different plug? If so, I think I need to consider something in writing about that with the dealer when I purchase it. I'd hate to have to go to the dealer for something as simple as that, but there are just so many reports of it that it worries me.

The trucks I am looking at have 50-70K miles on them so I figure I would have to deal with this before too long.

Sorry if this has been covered before, I have been looking all over but am getting a lot of conflicting information and need to clarify it pretty quick. It's really the only thing scaring me off a nice '04 Lariat right now. I don't like the thought of a simple plug change resulting in a day or two of downtime and upwards of $1K out of my pocket. I was burned on a '98 Explorer and am very leery of going back to Ford, but I also don't like the competition in that price range all that much.

Any assistance is appreciated,

A (hopefully) future f-150 owner,

Phil

 

Sounds about right. The breaking plugs was an 04-08 body style issue. Not exactly sure when the heads/plug change was made to "remedy" the situation. I have heard 2 different stories, the plugs were changed to 1 step hotter to burn the carbon that builds up and causes the friction, or a slight taper to where the plugs come into the head. I have an '04 5.4 and changed the plugs at 42k. My mechanic got all 8 out without any breaking. I ran good fuel and a can of K44 (or 44K, don't remember, lol) before performing the change in accordance with the TSB for it. Also, I replaced them with the 1-piece replacement plug.

Also, some '05s had injector issues and possibly clogging or continually dripping, but Ford extended an 11 year (to sure on miles) warranty on all applicable motors.

With all of that bad stuff being said, I am not discouraging you, just agreeing with your previous statement. I love my '04 and would buy another if I needed to.

Whatever you do post pics and the price of the truck and the guys/gals here will give you their take on a fair price.

 

plmn- if that 04 is a good price id buy it quickly. there was a truck i had my eye on and it was sold a couple days later after i had looked at it.

 

If it were me, I would buy the truck with one condition. Tell them the deal can be made if they will do a PLUG change before you take delivery. Let them know up front that you have done your homework and that has you very concerned. If the mileage is around 60k, tell them the plugs are about ready for a change anyways. If they want to give you a hard time, do some research on the net before you go make an offer and hand them a stack of paper showing them that there is issues with the plug change and you do not want to go through the nightmare of that problem. If they really want to move the truck they should comply. At least the dealer I go to, would do it, without hesitation. I wouldn't hurt to ask them to show you the plugs they removed. Hopefully they are honest and would show you the plugs that they actually removed. I have a 1998 in excellent condition but the day will come in 2-3 yrs where I will trade it and I will be making these demands or I will not buy the truck.
Good luck with the purchase.

 

Phil

I had an interesting discussion with my long time mechanic last night on this very subject. Happens I'm picking up a 07 with 20K on it the end of this month and both wanted to make him aware of it and see if he had any advise as I'd also heard of the plug issues in the 5.4.

His comment was that yes it's expensive if a plug breaks, yes it's a known problem and yes there is a fix. He suggested that once I get it back here (have to fly out to get it and drive it back) that I bring it in and have the plugs changed out with some new designed plugs that get rid of the breakage problem. He was dealing with some work at the time and didn't have time to stop to go into detail so that's all the info I have at the moment.

He's maintained my vehicles for about 10 years now and I trust him when he says there's a problem or solution to one. I'm planning to do just as he says, once I get it back to have him change out the plugs to the new style.

Good luck on your purchase selection

Paul

 

Yes that had crossed my mind, or at least have it in writing that in the future they will change them at the standard cost regardless of if they break them or not. May have already been done, now I know to ask if they are one-piece or not.

I'll be going to look at it tonight, these things do seem to move fast. Thank you everybody for the responses and if anybody knows anything else keep 'em coming.

Thanks again,

Phil

 

Honestly, I wouldn't wait for the future plug change. Have them change the plugs out for peace of mind when you leave the lot. You can be promised anything in the future, things change.

 

Yes, there is a problem with the plugs breaking, but to me, it has been blown way out of proportion. If the dealer knows what they are doing, follows the TSB, they can get them out. Mine were changed at 65,500 and none broke. I went back with Motorcraft plugs. I expect they will come out too at about 90,000 miles. Even when they break, they can be extracted fairly simply, if they know their stuff.

Having said that, I would get them to change the plugs for you as part of the deal, but I would not let it be a deal breaker, if I liked the truck otherwise.

 

HCBPH, your mechanic is probably referring to the Champion one piece plugs. They eliminate the breakage issue, but otherwise people have been having very mixed results with them. If you do that, plan on changing them every 30k. That can get expensive at 20 bucks for each plug BEFORE labor.

 

Exactly! The fix for the 04 to early 07's is Champion ONE PIECE plugs. Federal Mogul stepped up to the problem, while Ford took a seat. The Champions have been doing very well in the 3 valves.

BTW- Nice job Phil,- searching/investigating the problems. Most don't! Anyway, you're correct

 

so the 09 5.4 plugs are 100% percent trouble free now??

 

Yep! So are the 08's.

 

Everything I assemble, I assume that someday I'll have to disassemble.Anytime you mix steel with aluminum you'll have corrosion that locks the two metals together like a welder.A jar of nickel based anti-seize is worth much more than gold. The tiny amount you put on the threads can prevent major disaster when taking things apart years down the road.I turned the plugs out of my 2000 a few years ago when I heard that some trucks had the problem.I took them out a couple days ago and the anti-seize was still there and they came out like I just put them in.Good insurance.

 

Yea, DON'T use Anti-Sieze on the 97 - 03 (most 03 models). You have 4 thread heads that don't need any help w/plug removal lol. The older modulars have been known to spit plugs and Anti-Sieze makes it worse.

Use Anti Sieze on the 04 + . 2, 3 and 4 valves only.

 

Pardon my ignorance but why is there such a difference in mileage between the scheduled tuneup using the original Motorcraft style plugs vs the Champions? Even at $160 plus labor, that's not too terrible with the amount I drive any more if it keeps everything running right.
Just curious

Paul