socket won't engage spark plug - a solution
That's cool. 
Junior Member
Joined: Aug 2013
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i know this is a very old thread but frickin-ay it worked. now i have to call up a bunch of mechanics who refused to work on my truck because they wouldnt believe me when i told them i did not have the engine with the spark plug problem. i was quite literally told "yeah sorry but we're going to have to pass" WTF!!!
Junior Member
Joined: Sep 2018
Posts: 1
Likes: 1
It worked.
I'm posting this because I think this could be a common problem, and I came up with a solution that could save someone from hours of frustration or failure.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
I think its funny how people replying back in 2013 thought it was an old thread but im sitting here replying to a post almost 10 years old. Anyways, this was an ingenious thing and has helped me a lot. The copper was just the right size and easy to cut teeth on. I will be referring others to this post. Very helpful thank you.
Junior Member
Joined: Jan 2019
Posts: 1
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i can confirm, used the search button, and found this. #2 and #4 spark plugs I could not get the 9/16" spark plug socket onto them. Found this thread...and got me a short section of 3/4" pipe, cut a notch..and BAM! got the plugs out!
I was out there for about 3 hours total trying different sockets and looking down in there....questioning my sanity lol.
I guess a lil dirt down there really screws it up
I was out there for about 3 hours total trying different sockets and looking down in there....questioning my sanity lol.
I guess a lil dirt down there really screws it up
Junior Member
Joined: Apr 2019
Posts: 1
Likes: 0
OHHH baby this is genius im having this problem with 3 plugs major dirt build up. Going to try this now, ill be so damn happy to get these plugs done omg. THANK YOU
edit: worked like a charm! just used the pipe then compressed air and repeated a few times until i had enough to grab with socket. Thanks again your a genius.
edit: worked like a charm! just used the pipe then compressed air and repeated a few times until i had enough to grab with socket. Thanks again your a genius.
Last edited by Warren Tanner; May 1, 2019 at 01:08 AM.
Junior Member
Joined: Jun 2019
Posts: 7
Likes: 0
From: Kans ass
wish I would have read this yesterday.
Having exact same problem. I replaced the first 7 spark plugs in just over an hour. I started with the drivers side because I figured it was the harder side to access so might as well do it while I’m fresh. Got to the last one ( passengers side all the way in the back under the heater hoses and fought it for 3 hours. Never could get a socket on it nor could I get the spark plug wire boot to snap down on it so as of right now I have a miss. I will be looking for a piece of pipe to try the method described above. Thanks for the info.... good stuff!
Junior Member
Joined: Jun 2019
Posts: 1
Likes: 0
I'm posting this because I think this could be a common problem, and I came up with a solution that could save someone from hours of frustration or failure.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
Junior Member
Joined: Aug 2020
Posts: 1
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I just bought a 97 f150 with a 4.6 ran like **** needed a tune up I go to do it and there is dirt and gunk half way up the spark plugs so I got to town with a flat head and a compressor and got all but that same plug as you and I had no idea what to do. So thank you this post helped me out greatly
Junior Member
Joined: Aug 2020
Posts: 1
Likes: 0
thanks
Thanks so much it did the trick for me the end of the rubber boot over the coil broke off when removing old coil and was lodged in the hole your solution did it for me after hours of frustration. OTE=dbischoff;4083046]I'm posting this because I think this could be a common problem, and I came up with a solution that could save someone from hours of frustration or failure.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.[/QUOTE]
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.[/QUOTE]
Junior Member
Joined: Mar 2021
Posts: 1
Likes: 0
I'm posting this because I think this could be a common problem, and I came up with a solution that could save someone from hours of frustration or failure.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
Junior Member
Joined: Mar 2022
Posts: 1
Likes: 0
I'm posting this because I think this could be a common problem, and I came up with a solution that could save someone from hours of frustration or failure.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
I recently changed the spark plugs and COPs on my '01 4.6. Thankfully, I was relieved to read that the 4.6 does not have the scary spark plug breakage issues that the 5.4 has.
However, I spent almost a whole day to accomplish what should have taken a few hours at most, all because one of the spark plug tubes in the head had dirt buildup.
I was stuck trying to remove the spark plug from cylinder #4 (rearmost, passenger side). Either the socket was not going over the plug, or the plug was somehow spinning freely and not coming out.
The #4 plug is way in the back, tucked under the firewall, so it is impossible to look into the tube to see what is going on. I tried unsuccessfully to reach a finger in to see if I could feel the plug. There's just no room.
I tried reaching in with pieces of coat hanger wire to see if there was a rock, bolt or something in the hole that was blocking the socket. Again, without being able to see, and having to make a bunch of twists and turns to reach it, I had no control of where the wire was going. My attempts to drag the wire around the outside of the plug hoping to catch something were futile.
I even epoxied a small rare earth magnet to some thin wire to see if it might pull something up.
I tried putting some paint on the inside of the socket so that I could tell by the scrape marks if the socket was actually going down over the plug. It wasn't. This was my first partial success, because it proved that the spark plug and threads were intact and not just spinning freely in the head.
I tried spraying penetrator into the hole, but I couldn't reach it so I couldn't even tell if any was going in.
After hours of futility I had a brief moment of brilliance:
I was looking at the long spark plug socket and I realized that it's outside diameter is about the same as the 3/4" copper pipe that a lot of us have in our houses. And the copper is thin enough that it would be able to clear the nut on the spark plug.
I had some scrap in my workshop, so I cut a piece that was long enough to portrude from the spark plug hole if it was shoved all the way down, but still short enough to maneuver under the firewall and into the hole.
I used a dremel ( a file or hacksaw would work) to cut a big barb on one end. Its like a hole saw but with only one tooth.
I shoved it down the hole and gave it a few turns. It came up with a bit of dirt on the end, so I tried some more, and re-attempted the spark plug socket. It was making a difference, but still not working.
With the copper pipe in the hole it gave me a target to aim a big shot of PB Blaster (penetrator) I sprayed it inside the pipe, and gave it a few more twists, then pulled it out and tried the socket wrench again.
Success!!
The problem all along was just dirt surrounding the spark plug nut. I was surprised that it could so easily block the socket wrench.
When I finally got the plug out I noticed that it was much older and worn than the others. I bought this truck second-hand. Someone before me had the same problem and gave up, as I almost did.
The spark plug holes point straight up, and even with the rubber portions of the COP filoing them, I guess it leaves room for dirt to get packed in there.
Oh, and one other thing. Changing the COPS on the driver's side of the engine is more difficult because there is more stuff in the way. In particular there is a big **** thingy on the fuel rail that gets in the way of one of them. I didn't have to pull the fuel rail off, and I didn't want to either, because I was afraid of losing the o-rings. I just removed the two bolts that hold it to the throttle body, and that allowed it to flex just enough for the 7mm socket to fit past it.
I hope this helps someone.
Senior Member
Joined: Sep 2019
Posts: 131
Likes: 6
Not as good as a compressor,but better than nothing... a shop vac. Duct tape a flew straw into the hose or the crevice tool. Or, a pc of garden hose, or 1/4" fridge water line.
(The last one can even reach inside a cylinder and be rotated to reach all the piston top's perimeter, unless the piston is too close to TDC. It's awkward, it being permanently curved tubing, but hey... it's an emergency if you're doing that.)
And some if these tricks work w an air compressor, too.
(The last one can even reach inside a cylinder and be rotated to reach all the piston top's perimeter, unless the piston is too close to TDC. It's awkward, it being permanently curved tubing, but hey... it's an emergency if you're doing that.)
And some if these tricks work w an air compressor, too.
Junior Member
Joined: Apr 2023
Posts: 1
Likes: 1
Finally!
'99 4.6L and same story nearly verbatim. Misfire cylinder 8 replaced coil packs (not COP'S on '99) Plugs and wires. 5-8 were deceptively easy if you move the PS reservoir out a bit. 1&2 were also simple. 3&4 were literally the same issue. The coolant lines leading to the firewall were leaking, and all the grime in the hole wouldn't allow my plug socket down enough to engage. 13 years later, and this thread is a lifesaver. I also had random plugs. Mostly Motorcraft w/ a few autolite, which leads me to believe someone was lazy and only changed plugs as they failed over the course of 24 years and ¼million miles.
Junior Member
Joined: Apr 2025
Posts: 1
Likes: 0
Thanks you so much struggled with this for awhile at least 45 min, was frustrating. Found an old chunk of tube carved some teeth into it pulled out a bunch of gunk. Took 5 min to change the plug. SUCCESS! Thank you 😊