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 - Usin Your Implements: Bucket Loader - by Curtis Von Fange. Introduction: Dad was raised during the depression years of the thirties. As a kid he worked part time on a farm in Kansas doing many of the manual chores. Some of the more successful farmers of that day had a new time saving device called a tractor. It increased the farm productivity and, in general, made life easier because more work could be done with this 'mechanical beast'. My dad dreamed that some day he would have his own tractor with every implement he could get. When he rea
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