Ford lost a lifetime customer!

[ktpking]

Well how should I start? My brother in law called and asked if I would help change out his spark plugs on his 2004 F150 truck. I started on the first plug and SNAP the damn thing broke in half. I said oh shit I have never had that happen before. We went in and called the dealer's parts counter and asked if they had a tool to remove the broken plug and he asked what type of car I had and told him. He said uh oh, I'll transfer you to service.

The service guy answered the phone and told him of the situation. He said it is a very common problem with the year and motor. He said it was bad engineering on Fords behalf but, since then they have corrected the issue. Well, my brother in law was shit out of luck. He said have it towed in and they would change out the plugs but cannot give an estimate because it takes a long time to change out a broken plug and it depends on how many plugs break. I told him we would get back with him.

Well, in short he was pissed. We called around to some local garages and they told us they did not do that year of the truck because of the issue. One garage had to eat lots of labor because they quoted the customer a price and stuck with it not knowing about the problem. Soooo, I called a Napa and they sell a tool to take out a broken plug but, it cost $120 and takes about a half hour to take one broken plug out and you have to have a compressor to blow the porclin from the broken plug out of the hole to make sure it does not get into the engine.

He had his truck towed into the shop and guess what? They called the next afternoon and told him his truck was ready. Total bill for changeing out 8 spark plugs.......$1048.52

He was steaming hot needless to say. He politely told me I could take my A-Plan and shove it up my ass, because he will never buy a Ford again. I have been looking around on the internet and holy shit! There are a ton of people haveing the same issue. Looks like a class action lawsuit is comeing to try to rectify this situation by some of the comments made. I told him of this and he has since kept his reciept and all the old broken plugs.

I just wonder if you put the stock plugs back in will you have the same problem next time you try to change the plugs out?

forums.motortrend.com/70/6398907/the-general-forum/ford-has-screwed-up-withthe-f150-spark-plugs-can-i/index.html

autoforum.classifieds1000.com/Ford-F150/Spark_Plug_Nightmare


www.carcomplaints.com/Ford/F-150/2004/engine/spark_plugs_break_off_in_head.shtml



Wow, just wow! Looks like they have a TSB but, from what I read this TSB does not work. They still break.

[wallflower]

There are methods to increase your chance of success, but few are foolproof. It is a bad deal for sure that will continue to give Ford a black eye for some time to come.

[Jr]

it's been going on for a long time!!! I've got a 99 Expedition with the 5.4 wait they decide to shoot a plug out of the head, threads and all. I've had 3 redone already. This starts after a plug change. and usally takes out the coil at the same time.

[ktpelec]

Jr, and Wallflower are right on, it's not only that particular year. The "modular" motor design has several flaws, though it is a good engine. The dealers all have several bad engines laying around, they basically can't be rebuilt, just throw them away and get another. My uncle experienced the same thing Ktpking, he had 150,000 mile on the engine though with almost no maintenance issues before that.

[Mr Happy]

1048.00 WAS A DEAL!! They wanted 1800.00 for my truck if all 8 broke.....

[driveshaftgrunt]

Has this thing been fixed?

At what model year was this problem corrected.....

Surely to GOD its not still an issue........

[Deleted]

Every car mfgr. has flaws from time to time. This one really does give its owners a black eye.

[ScottR@KTP]

The V-10 has several issues with blowing out plugs as well. I have the V10 in my Super Duty and I hope to be able to part with it before this ever happens.
If I can get to 100,000 miles with no problems with the drive train...that's usually my time to move on to the next Ford.

[ragtop69]

I have had lots of experience with these motors and plugs. In won't touch it without an understanding that I am not responsible for broken plugs or damage already done, after that is understood, take the ignitors out and spray PB Blaster or WD40 in the hole on a COOL engine. Do not remove the plugs from a hot or even warm engine. I will only take oiut the plugs after it sits and soaks overnight. Snap on makes a extra long socket to remove the plug that also helps alot. Hope this helps.

[Jr]

OH Yeh and If you blow a plug Ford will tell you that you need to replace the head!!!! Wrong they will hold with the right helicore.


Oh yeh Ragtop how may Cougars you got Now Got any 67's

[wallflower]

A heli-Coiled head is stronger than a plain aluminum head. You have more surface area in contact with the aluminum through the larger diameter of the heli coil versus the plug. Then the plug screws into the steel heli-coil insert.

[ktpking]

Jul 17, 2010 12:23:10 GMT -5 ragtop69 said:

I have had lots of experience with these motors and plugs. In won't touch it without an understanding that I am not responsible for broken plugs or damage already done, after that is understood, take the ignitors out and spray PB Blaster or WD40 in the hole on a COOL engine. Do not remove the plugs from a hot or even warm engine. I will only take oiut the plugs after it sits and soaks overnight. Snap on makes a extra long socket to remove the plug that also helps alot. Hope this helps.

If too much of the wd-40 or whatever gets into your engine you could cause vapor lock and destroy your engine.

[ktpelec]

Jul 17, 2010 12:23:10 GMT -5 ragtop69 said:

I have had lots of experience with these motors and plugs. In won't touch it without an understanding that I am not responsible for broken plugs or damage already done, after that is understood, take the ignitors out and spray PB Blaster or WD40 in the hole on a COOL engine. Do not remove the plugs from a hot or even warm engine. I will only take oiut the plugs after it sits and soaks overnight. Snap on makes a extra long socket to remove the plug that also helps alot. Hope this helps.

I assume it was take the "injectors" out. That could be a problem if too much WD-40 gets in there Ktpking, it would "hydro-lock" the cylinder, possibly flatten a rod bearing, I've seen water do it to an old school motor.
My fathers F-150 is an 03 with 90,000 miles, I told him to get ready to pay or trade.

[Jr]

I think he was talking about the coils and calling them "ignitors" You can't even get to the spark plugs unless you pull the coils

[Mr Happy]

Jul 19, 2010 8:28:34 GMT -5 ktpelec said:

Jul 17, 2010 12:23:10 GMT -5 ragtop69 said:

I have had lots of experience with these motors and plugs. In won't touch it without an understanding that I am not responsible for broken plugs or damage already done, after that is understood, take the ignitors out and spray PB Blaster or WD40 in the hole on a COOL engine. Do not remove the plugs from a hot or even warm engine. I will only take oiut the plugs after it sits and soaks overnight. Snap on makes a extra long socket to remove the plug that also helps alot. Hope this helps.

I assume it was take the "injectors" out. That could be a problem if too much WD-40 gets in there Ktpking, it would "hydro-lock" the cylinder, possibly flatten a rod bearing, I've seen water do it to an old school motor.
My fathers F-150 is an 03 with 90,000 miles, I told him to get ready to pay or trade.

A 03 should be ok the 2 piece spark plugs and the breaking issue didnt start til 04 and ran thru 08(11 diff. vehicles) this is a different issue from the plugs blowing out. Best advice is to change them early if you wait til your 70k + the carbon will build up causing problems. Run a bottle(or 2 ) of some type of injector cleaner thru your engine before attempting, like was mentioned use pb blaster in plug wells after turning the plugs slightly and let it soak(cold engine,pb blaster wont hydro-lock if you dont over do) take your time. Rotundu makes a kit for this job if they break part no. 303-1398, there is 3 different ways to break them 75% of the time it will be the ground sheild stuck in the hole and you'll need the kit or make your own. All this info can be found under TSB 08-7-6 read it carefully and follow directions and it's not that bad, if you dont you can make a very costly mistake