Changed my spark plugs. 3 of them broke

[Throckmorton]

On the Ford modular V8 engines up to about 2008 they used 2 piece spark plugs because of the length required to reach the cylinder. Extra length comes from an extended ceramic piece surrounded by a separate metal sleeve that is pressed in to the threaded metal part. That might be fine, except carbon builds up around the sleeve so it sticks when you try to remove the plugs. The ceramic breaks and stays behind in the sleeve. The Ford TSB says to soak with carb cleaner which helps but not 100%. 3 out of 8 broke.

Lucky for me my brother was a Ford mechanic (now Land Rover) and he was helping me... i.e. doing all the work
He had no problem getting the pieces out with my new Lisle removal tool.

The old ones were factory original with 126k miles and the new ones are Brisk one piece so the next change should be easy.

FYI if the dealer breaks your plugs, you are the one who pays the additional cost, even if they have to remove the heads. Ford decided it was most cost effective to screw its customers.

 

[Fritzo]

I know there was a storm brewing over those Ford plugs. Not sure if it turned into a class-action lawsuit or not.

 

[drnickriviera]

did you have a problem with the porcelain pusher pushing it to far down and snapping the electrode ground loop? The instructions told you to keep going until the nut stopped, but I started going at least a 1/4" from full stop.

 

[Throckmorton]

did you have a problem with the porcelain pusher pushing it to far down and snapping the electrode ground loop? The instructions told you to keep going until the nut stopped, but I started going at least a 1/4" from full stop.

No, the ground loop goes all the way across so I think it's pretty strong. My brother did it though so I don't know how much force he applied.

 

[Throckmorton]

In this thread they talk about turning the pusher until the "ground strap" snaps. Pretty stupid IMO, because you're HOPING only one side snaps, and if both snap you have a piece of metal in your cylinder.
http://www.f150forum.com/f4/i-really-need-badly-broken-5-4-3v-spark-plug-pics-96533/

 

[Throckmorton]

BTW the 3 that broke were all rusty. The other 5 weren't!

 

[Jimzz]

Yea Champion was the only aftermarket plug makers to come out with a 1 piece design back when this first started. I think ford (autolite is the maker, same company as Fram) also came out with a 1 piece later as well but most seem to prefer the champion from what I read.

 

[kitatech]

I've read on several forums over the years that one should not reinsert a plug after removing it (resulting in unseen compromised construction)...that replacing it with a new one is better practice.....many disagree, but it seems penny-wise, pound foolish for a $6-7 part that should last 6-7 years...

 

[Throckmorton]

I've read on several forums over the years that one should not reinsert a plug after removing it (resulting in unseen compromised construction)...that replacing it with a new one is better practice.....many disagree, but it seems penny-wise, pound foolish for a $6-7 part that should last 6-7 years...

With these plugs that probably has nothing to do with it. The narrow sleeve isn't stressed when it's clean, only when it gets carbon build up and sticks

 

[heymrdj]

This has certainly been a main issue for years. I had no issues with my 04 5.4L when I changed at 98k miles. I replaced them with single piece plugs. I'm at 132k now so it might be time for me to pull them and check the threads again.

 

[Ferzerp]

This is a dumb design!

Then again, the modular 4.6L from that era was a dumb engine anyway

 

[desy]

I remember when you used to changed plugs every year

 

[slag]

Not all modular fords used 2 piece plugs. I had a 97 with the 5.4 liter engine and it had a 1 piece plug. Never had a lick of problems with it either and it was a good truck for me. Modular plugs started in the 2000's I believe.

Yeah, just the 3 valve per cylinder ones used the two piece plugs. I just don't see how this made it production and even then lasted beyond one production cycle.