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  1. #21
    Senior Member 2004XLT5.4LTritonV84X4's Avatar
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    Matt Straw
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    Attachment 521

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    DSC04468.jpg

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    Attachment 516

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    Attachment 525
    Here's the hole with the plug in it. Sorry, bad angle...

    Attachment 513
    The puller in the hole....there is a nut that goes on it to do the actual pulling. And I missed getting a picture of the "pusher" of the ceramic piece. VERY easy to use!

    Attachment 512
    What stays in the head when it breaks off. Again, note the rust, that's what causes the problem. You can see the puller screwed into the plug in this picture. The puller goes inside the piece of aluminum that you can see in the previous picture, and then a left-hand nut threads onto the puller (a plastic washer goes on there too).

    Attachment 511
    Directions

    Attachment 510
    New materials! I went with Motorcraft plugs again....kinda maddening that they're made in Mexico through...I drive a USA made truck! Make sure to put a lot of anti-seize on them and you won't have this problem the next time (if you own it then...or the next guy). I also went ahead a bought new "boots" that go in between the plug and the coil, they didn't cost that much, and I figured it would be worth it. Make sure to put the dielectric grease on them too.

    Attachment 509
    What one came out as.

    Attachment 508
    What 4 unfortunately came out as...this is the big design flaw, the crimped on threads pull off of the plug itself. If they come out like this you will need to break the ceramic part...not a big deal, just do it and it's easy.

    Attachment 507
    What they're supposed to come out looking like. Note the rust on the lower part of the plug, that's what causes them to break off. It binds in the head and when you try to pull it off the outer part is all that comes.Oh, and by the way....you have to pull them out with a socket, you can't just pull the boot off and have them come LOL Yeah, just thought I'd mention!

    Attachment 506
    All the coils and boots....with some of the plugs.

    Attachment 514
    Pulling it out! Just so long as they squeak, you know you're good! Just like when you pull them out any other time!

    Here's some pictures of pulling the plugs that broke off....sorry it took so long to get them here. The way I tried to pull my plugs was by what one of my mechanics told me, he said he's had only two ever break off in his time. What he said to do was just to get the engine as hot as you can, and pull them out as quick as you can, just so long as they squeak on the way out you know they haven't broken. Start with the hard ones at the back. I do know that there is the danger of messing up the head (since they are aluminum), but I chose to go this way....at almost 120,000 miles then and never having been changed, it probably would've been better to go the slow and easy way as explained in the earlier part of this thread! Sorry some of the steps are out of order...it's really self explanatory when you read the directions that the tool comes with. It is a ton easier than I thought it would be, four of them took 5-8 minutes a piece (at most!) and one I had a little trouble with the threads catching on one. The one I had trouble with only took like 20 minutes, just make sure that if you have trouble with it catching that you don't push the ceramic in too far with the tool the metal piece on the end of the plug will break.....and you don't want to loose pieces in the cylinder. Good luck! Ask any questions and I'll be glad to answer what I can!
    Last edited by 2004XLT5.4LTritonV84X4; 03-11-2012 at 12:07 AM.
    2004 FORD F150 XLT
    5.4L Triton V8 4X4 SuperCab Automatic 6 1/2 bed 265/70/R17 Goodyear Wrangler Duratracs

  2. #22
    Senior Member 2004XLT5.4LTritonV84X4's Avatar
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    Matt Straw
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    Hey guys, sorry this is all messed up. When I went to add more pictures to it and make it more detailed it did this. Is there a way to get all the pictures on here that i want to? And maybe big like the ones at the beginning of this thread? Sorry again, I will try to get this fixed.
    2004 FORD F150 XLT
    5.4L Triton V8 4X4 SuperCab Automatic 6 1/2 bed 265/70/R17 Goodyear Wrangler Duratracs

  3. #23
    Super Moderator kozal01's Avatar
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    Quote Originally Posted by 2004XLT5.4LTritonV84X4 View Post
    Hey guys, sorry this is all messed up. When I went to add more pictures to it and make it more detailed it did this. Is there a way to get all the pictures on here that i want to? And maybe big like the ones at the beginning of this thread? Sorry again, I will try to get this fixed.
    Matt if you post the [IMG] link from your attachments they will show up full size.
    2005 F-150 Supercrew Lariat 4x4
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  4. #24
    Senior Member 2004XLT5.4LTritonV84X4's Avatar
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    [IMG]DCS04501[/IMG]

    Like this?

    ----------

    ok, are you saying like copy it off of the photo deal that pops up?
    2004 FORD F150 XLT
    5.4L Triton V8 4X4 SuperCab Automatic 6 1/2 bed 265/70/R17 Goodyear Wrangler Duratracs

  5. #25
    Junior Member chuck's Avatar
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    Quote Originally Posted by 2004XLT5.4LTritonV84X4

    Like this?

    ----------

    ok, are you saying like copy it off of the photo deal that pops up?
    9/16 plug socket. Pull plug till first one breaks. Tow to dealer. 800 US Dollars later. Plugs may work. This sucks

  6. #26
    Super Moderator kozal01's Avatar
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    Quote Originally Posted by 2004XLT5.4LTritonV84X4 View Post
    [IMG]DCS04501[/IMG]

    Like this?

    ----------

    ok, are you saying like copy it off of the photo deal that pops up?
    Yes, just like that

    Quote Originally Posted by chuck View Post
    9/16 plug socket. Pull plug till first one breaks. Tow to dealer. 800 US Dollars later. Plugs may work. This sucks
    You give up that easy?
    2005 F-150 Supercrew Lariat 4x4
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  7. #27
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    Is there a new replacement plug by Motorcraft that is one piece so you don't have this problem again? I have a friend that told me Champion makes one, he owns an auto service center, and used the Champions. Personally I've never used any other plug in my Fords since 1966.

  8. #28
    Super Moderator kozal01's Avatar
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    Motorcraft SP515 is a redesigned plug, its not one piece but the long end of it is smaller than the stock ones so them getting stuck will not be an issue down the road. IMO stick with Motorcraft, Ive not heard many good things about the Champions in these trucks. Ford motors have been picky with plugs for a while.
    2005 F-150 Supercrew Lariat 4x4
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  9. #29
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    I think you should be commended highly on this procedure. After reading your article I decided to change my plugs with 73,000 miles. Just took them out today, 3 broke. Have a friend thats going to loan me his Lisle tool, so hopefully will finish tomorrow. Once again, THANK YOU.

  10. #30
    Super Moderator kozal01's Avatar
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    Quote Originally Posted by zgoldwingman View Post
    I think you should be commended highly on this procedure. After reading your article I decided to change my plugs with 73,000 miles. Just took them out today, 3 broke. Have a friend thats going to loan me his Lisle tool, so hopefully will finish tomorrow. Once again, THANK YOU.
    Glad I could help! Good luck getting the broken ones out. Let us know how it goes!
    2005 F-150 Supercrew Lariat 4x4
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