Question about 2005 Ford F-150

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Spark plugs broken

04-05 Ford trucks and suv's with 5.4L engine have unique spark plug design with and extra long tip. They are designed to last at least 100K miles. Problem is that the extra long tip builds up carbon deposits and seizes in the combustion chamber. They will break off real easy especially on higher mileage vehicles. Ford has issued a TSB for suggestions on removing the plug and dealing with broken plugs. But if you google it, their are numerous examples of people having to spend $2500 to $3000 at both independant shops, and yes dealerships too.

These plugs are sooo good their are many instances of people going over 140K before they needed to be replaced. This is a TRAP, cause these are the ones that WILL break off. And if the spark plugs in the back cylinders break off--Then get out the credit card-big repair bill.!!

The lucky people with the best results have been the ones who changed their plugs before 60K. But Ford gets over $20 a plug !! Good newz is Champion recently came out with a "one-piece" plug that is less likely to break, and cost about 1/2 the price of motorcraft.

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Only fix would be, if you have can do your own work try to find a tool truck running around snap-on ,matco, mac they have a tool very easy to use a lot cheaper than paying someone to do .I know this is not much of an answer but these plugs will do this no matter what you do make sure you use penatrate in around spark plug whole a while before trying to take plug out get engine hot spray in penatrate let set.

Posted on Nov 23, 2008

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I have run into this problem already at my shop , what we did is make a special tool ,it was kind of hand , it basically was a rod with a easy out welded to the tip of the rod . it took about 15 min to come up with the idea ,and 5 min to get the broken tip out

Posted on Nov 23, 2008

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Spark plug gap for 503 Rotex


Hi Faye,

I found this,





Rotax spark plug advisory for ultralight, experimental lightsport, amateur built aircraft.




Rotax 2 stroke aircraft engine spark plugsThe recommended spark plugs for the Rotax 277, Rotax 377, Rotax 447, Rotax 503, Rotax 532, Rotax 582 are the NGK B8ES series or the NGK BR8ES ( the R in the spark plug denotes it is a resistor plug and should be used in all of the CDI ignition engines.



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Use spark plugs that have a SOLID TIP - DO NOT USE spark plugs that have an aluminum screw on tip. They vibrate loose, the tip wears making a loose cap to plug fit, and can lead to the spark plug arcking across from the cap to the plug. Also the screw on style spark plugs are NOT designed for our applications, the gap is generally set up for .030 to .035 thou. The solid tip spark plugs are set up for a gap of .015 to .020 thou.

Spark plug gap



  • Allowable range: 0.4-0.5mm / .015 -.020"


  • Optimal: I usually set them to .015 and let them wear out to .019


  • This also helps getting the engine started in colder conditions


This was found at

Oct 10, 2014 | Cars & Trucks

1 Answer

I had the Ford Dealer tuneup my expo. 2006 4.5L, in the process they broke 6 plugs and charged me $250 extra for the tuneup. I think that there is design problem with this engine and that Ford should pay ...


Over the last 10 years or so the ford engine heads have been know to have the plugs seize up in them and snap when trying to remove them, The plugs have striped and blown out of the cylinder heads and the heads have cracked due to heat problems. You could call the ford rep for your area in Detroit and file a complaint about the dealer to see if you can have your money refunded or you can take them to small claims court for them not fully informing you that the plugs may snap off trying to remove them and you'd be charged extra for the time and labor of removing the broken plugs from the heads. Hopefully they gave you back all the broken plugs and used parts to prove that they actually did break off. Also Laws vary from state to state, you may be screwed and can do nothing.

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The repair man broke 6 plugs while tuning up my engine (5.4L) and I was charged $250 EXTRA the job. My problem I think is in the Design and Ford should be charged and not me!


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My car turns over just fine but it want start. What do you think that is?


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Is there a design weakness in Ford products over the issue of spark plugs blowing out and if so, will Ford Motor step up to the table?


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2 Answers

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