The problem is aluminum heads that are real thin in the spark plug area. So you have a very few threads holding the spark plugs in. In some engines it is only four threads from the factory. The aluminum expands and contracts during heat cycles. This causes the threads to wear/weaken. Also the engines running cleaner lets the plugs be in the head up to 100k before the recommended tuneup interval.
So carbon builds up on the bottom of the plug which makes it more prone to seize when being removed. Ford knew of the problem as early as 2006 when they issued a service bulletin with removal instructions and special remove tools to help get the broken plugs out.
So you have a bad designed that was kind of brought on by Ford having to make the engines run hotter to met the EPA regulations.
A good friend had a Ford F250 with a 5.4 blow a spark plug out of the right head at 75K. Plugs had never been touched but Ford told him it was a wear item and would not cover any of the cost of the repair. So a spark plug is a wear item???
Ford also has major issues with their 4.0 OHC engine too. Same friend had a Mercury Mountaineer with 88K shreading the timing guides and ruined the crank with metal shavings. Once again Ford did nothing to help him.
He is now driving his first GM product. He is 61 years old and been a loyal Ford new vehicle buyer,but no more.
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Today's Featured Article - Madison's County - by Anthony West. Philip Madison has been a good friend of mine for quite some time. He has patiently suffered my incessant chit chat on the subject of tractors for longer than I care to remember, and on many occasions he has put himself out, dropped what ever it was he was doing, to come and lend a hand cranking handles, or loading a find onto a trailer. Although he himself has never actually owned or restored a tractor, he was always enthusiastic and always around helping with other peoples projects.
... [Read Article]
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