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.
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.
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
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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.
BUT the Bosch points ignition engines should NOT use both a resistor plug and a resistor spark plug cap - use one or the other.
The least expensive option in the long run is the cap as you purchase it once while the resistor plugs cost more than the standard plug each time you buy them.
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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
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.
That would depend on whether or not the technician broke them because he is a poor tech, or whether the engine itself is at fault. I'm sure Ford will only accept liability if it is a design problem. Otherwise the technician may be held liable.
99 percent of the time this is because you are without fuel or spark. car is almost 20 years old so anything and everything is well beyond its designed life. Pull a spark plug out, connect it to its wire and lay it on the engine block and have someone turn engine over a few times. If you see a spark on the tip of the plug, then you have spark and you should look to fuel supply issues. if fuel injected look to the pressure regulator or fuel pump or bad injectors. if carburetor type look at fuel pump.
Ford states there is NO design flaw, although every shop mechanic will tell you that it is a common problem. I have a 03 f-150 supercrew w/ 5.4 motor & I'll tell ya," They couldn't have made those spark plugs any harder to get to. Don't get me wrong, they're do-able, but all the preventive actions you must perform are crazy. If you haven't changed them before, here are some tips: 1- DEFINATELY let the motor cool down 4 a few hrs. I believe that the spark plug blow-out problem stems from the aluminum head. When heated aluminum expands,so, I believe, when people try replaceing plugs with the motor warm, the plug doesn't get seated proper or proper torque. 2-After removive the coils,Use high pressure air nozzle & blow out the hole where the plug is located. Then use a shop vac & vacuum out any debris that can fall into the cylinder or restrict the plug from seating properly. As far as Ford, they say take your vehicle to your local dealer. Good Luck. I hope this opinion helps
With the advent of platinum tipped spark plugs and distributorless ignition a tune-up doesn't consist of much. Air filters (engine and cabin if equipped) should be replaced at 30k mile intervals (more frequent if in dusty climates). Spark plugs and PCV valve should be replaced at 100k mile intervals. The fuel filter is built inside the tank and is designed to last the life of the vehicle.
So basically if your at 100k miles you should replace the air filters, pcv valve, spark plugs and wires(if equipped). That is the extent of a "tune-up" now a days.
typically when you break a spark plug, it is the ceramic portion that breaks. the bit left in the engine would still be removable. if your worried, just spray a little bit of wd40 on the plug and let it sit for a few minutes. they should come out alright... just take care not to break the new ones on installation