I really could use some advice from anyone who has changed out plugs on their truck that has the "direct over cylinder" plug caps. I tried to change out my plugs over the weekend and had some real difficulty. The fuel injector rails are situated right atop the plug caps, so I figured that by relieving the fuel system pressure and pulling the rails, I'd have enough room to change out the plugs... no such luck. The front 2 plugs (4 total) on either side of the block are easily accessible when the injector rails are removed, but the back 2 sets (especially passenger side) are WAY back. I removed the plastic throttle body cover, but still had many hoses/cables to deal with and not enough room to get my 3/8" SPK way down deep into the cylinder to remove the plugs.

Can anyone give me some advice?

 

i see you have a expy. does it have aux a/c ? those really bite. your going about it right. just need the right combo of extention's and bandaid's when it's done. for those cool cut's all over your hand's, hehehe. sorry, not more info. but good luck.

 

You pulled the fuel rails?????Oh-no...

I know on the f150's you dont have to pull the fuel rails....

It takes an assortment of extensions and then twist over the coils and plan on buying a couple of boots if you have lots o'miles on the engine...boots are cheap at $3 apiece...I see alot of cracked ones when I change them....

Patience is a virtue!!!!

Plan on a good afternoon if you have never done them before...

 

Not a fun job. You really need to use 1/4" with an adapter using various size extensions. Loosen up the plugs and then use a spark plug socket so you can retrieve them from the holes. Use a piece of hose fitted on the end of the new plug to put the plug back down in the holes, REMEMBER to vacume the dirt/grime before you pull the old plugs. If I remember right the rear passenger plug was the worst. I disconnected to fuel rails and removed the injectors to level the playing field. Also removed the throttle cover, and air intake plenum. Also don't forget anti-seize for the threads and lube for the plug boots. Good luck.

 

For removing the coilpacks, a 7mm socket w/ the built in swivel is the best thing you can use to remove the bolt that holds them in.

 

The best spark plug installation info on the 5.4 L motors came from a post by a member of the NLOC and was directions in great detail on the install. I have used it many times for changing these plugs on the 5.4. Do a search over at NLOC for spark plug install and see if it comes up. I printed out a copy of it so I will always have it for reference. I am sure that some other menbers here know the post that I am talking about. Later 95rcobra.

 

HOLY S%#$.

I tried to change the plugs on my Mom's expedition. I was not as determined as you were about it. I took a look at it, and when i realized i had to take an assortment of covers for various crap off, i knew i was really in for it. Didn't proceed much farther than that. It has been my experience that the new Fords designed in such a way that you keep your hands out of it.
Before anyone flames the hell out of me, how hard would it be to leave half the crap off the top of that 5.4 and design everything else so that it is at least somewhat easy to work on things that require maintenance on some kind of schedule, i.e. plugs, caps, rotors, etc. A plug job should never require more than 30 mins to do.

im not trying to **** anyone off, but does anyone else feel like Ford went to some trouble to make it difficult for the owner to work on it?

 

95Cobra,

I attempted to access the NLOC website that you mentioned
but was unable to find it. If you or anyone has access to the informtion regarding changing the plugs on a 99 5.4 I would love to get a copy just for a reference. Could you maybe e-mail it to me???

thanks.

 

Hey Timberghost,
I went to search for it too at NLOC but it was probably lost when that site went down for a couple of weeks recently. I will write out that post here so others will have it for reference too. Here goes:

The first thing you need to know is where to release the wire connector to the coil pack. it is on the back of the the connector in the middle near the bottom. you push up on it to release.

Tools needed are 3/8" ratchet with (2) 6" extensions, (2) 3" extensions, 5/8" spark plug socket, 1/4" ratchet with (2) 2" extensions, (1) 4" extension and 7mm socket. the 1/4 inch extension will make it easy on the 3rd 7mm bolt back on the drivers side because the regulator sticks out of the fuel rail making it a tight fight. 1/4 inch extension will get in there.

You do not have to move the fuel rails or power steering tank brackets to do this job. Disconnect the wire to the coil pack then remove the 7mm bolt and twist the coil pack back and forth. the coil should come right out with a long rubber boot on the end. wipe the boot if there is any dirt on it and if you have a air compressor blow out the hole before removing plug.

The 3/8" ratchet, (2) 6" extensions and plug socket do most of the work. the passenger side 4th plug takes a 3" extension in the plug socket to make it in the hole because of a metal hose in the way.

On the drivers side the first plug takes all of your 1/4" drive extensions to get the 7mm bolt out because of a bracket. this bracket is also over the plug hole. now just use your 3" extension on the plug socket and go in from the front of the truck. then put another 3" extension on it and take it out with no problem. it helps to unplug the hard plastic hose from the rubber intake boot for more room.

The only other problem is the 7mm bolt on the 3rd plug back on the drivers side. it is too tight to get a regular size socket in there but if you use a 1/4 extension with 7mm socket it will get in there and do the job. by having the right tools in the certain situations will help to speed up the job. it should be a 2 hour job or less if everything goes well.

Tips: put anti-seize on your plugs and start the 7mm bolts and the plugs by hand before putting a ratchet to them. you dont want to crossthread the aluminum. hope this helps.


I personally started doing it this way in the beginning and varied it slightly to make it quicker and now I can do the plugs on the 5.4L in a little over an hour. practice makes perfect. good luck 95rcobra.

 

Thanks for your time 95Cobra. I'll print it off for future reference.
I just wish that my truck could be as easy to work on as my Mustang is! Thanks again!