Ford Spark Plug Removal Tool – Picture of Ford’s Bad Design
November 23, 2008 10:44 am Automotive Consumer, Automotive Specialty Tools, Lisle Auto Specialty Tool 
If Ford’s poorly designed spark plugs would just all come out like these.
The lucky guy that removed the spark plugs in the picture above, has someone watching over him, he narrowly escaped huge spark plug problems. We have orders everyday for specialty tools to remove broken spark plugs from Fords. The two piece spark plug typically comes apart, separating the main part of the spark plug from the huge electrode shield. Ford’s spark plug design comes under the heading “what were they thinking?” DenLors Tools was one of the first automotive tool suppliers to sell the Rotunda 303-1203 specialty tool that was recommended in the Ford TSB to remove these broken spark plugs when they were broken upon removal. Now, we have a much better solution in the LIS65600. The Lisle specialty tool has quickly became our most popular tool for removing Ford broken spark plugs. We have had only positive feedback from auto techs that have used this tool. Ford forums have recently been helping to spread the word of the success of this new tool. There is quite a buzz about a Ford class action suite regarding this poorly designed spark plug, but our role is to help those that are dealing with broken spark plug problems, to remove them as quickly and inexpensively as possible.
See the pictures below of the best tool for removing the broken electrode shield. I did a demo at a local shop to show how great this tool works. In fifteen minutes it was out and that was my first time using the tool.
Pusher in place, it screws into the spark plug hole and the center is ran down all the way.
Puller in place, after the porcelain is pushed down to allow access. Apply slight pressure so the self tapping tool can bite into the sleeve.
Notice the electrode is broken but holds the porcelain from going further, also the tool only goes so far.
Success!
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dennisb on the Ford Spark Plug Removal :
Date: December 25, 2008 @ 1:50 pm
Our last blog on this tool has some comments from previous users of the 303-1203 alternative.
Mike Maddison :
Date: February 23, 2009 @ 3:57 pm
As the porcelain is pushed down and breaks the electrode, does any part of the broken metal electrode fall down into the cylinder?
dennisb - Auto Tool Sales :
Date: February 23, 2009 @ 4:05 pm
There has been no reports of this, but it is a good recommendation to take a look at the plug’s electrode when it’s removed to see. It would be fairly easy to see if a piece is missing as long as you know to look.
Jim Swearingen :
Date: March 24, 2009 @ 9:13 am
I am not clear on what actually breaks the electrode strap.. Is it the porcelain, or part of the tool??
dennisb - Auto Tool Sales :
Date: March 24, 2009 @ 9:24 am
The tool threads into the spark plug hole, then the pusher is tightened forcing the porcelain down further which breaks the electrode strap. As mentioned before, just make sure no piece of the electrode strap is missing – that would mean part of it may be down in the cylinder. Although we have had no reports of this happening. Then proceed with the next step of using the self tap to remove the electrode shield.
Jim Lasalle :
Date: March 29, 2009 @ 9:18 pm
Poor manufacturing procedures intended to drive the Ford buyer back into the dealer’s vice for maintanance. Some more of Ford’s poor engineering. You and I both know they test this stuff. No wonder they need someone to bail them out.
matt :
Date: March 31, 2009 @ 4:58 am
What are you supposed to do if part of it falls into the cylinder. Seems kind of mickey mouse using the porcelain to break the strap inside the cylinder. I don’t I’m just saying that if did you could be in trouble. I guess the only thing you could do at that point is try and get a really small hose and vacuum it out?!?
matt :
Date: March 31, 2009 @ 5:01 am
Dumb question, does it come with instructions?
dennisb - Auto Tool Sales :
Date: April 4, 2009 @ 6:32 am
Matt, Yes the Lisle 65600 does come with directions. I can’t really imagine the strap breaking at two different places at the same time…that’s what would have to happen for a piece of the strap to fall inside. And the porcelain stays in one piece. If you prefer the method of pulling the porcelain out, then tapping and pulling the electrode see the Calvan 39100 and 39200 on our site.
Rick :
Date: April 8, 2009 @ 6:22 pm
Would it be possible for the shield to be pushed into the cylinder while jacking the porcelain down?
dennisb - Auto Tool Sales :
Date: April 8, 2009 @ 7:03 pm
Rick, I don’t think that’s possible due to the taper at the top of the electrrode shield.
Rick :
Date: April 9, 2009 @ 11:02 am
Um yes, I see that in the photo now. Thanks for the reply.
Robert :
Date: April 20, 2009 @ 3:53 pm
Have you ever had reports of the porcelain breaking/chipping and falling into the cylinder? It would seem natural that the porcelain is weaker than the metal electrode ground shield?
dennisb - Auto Tool Sales :
Date: April 20, 2009 @ 6:25 pm
Robert, I understand your concern but we have had no one say that has happend. The porcelain is brittle but very strong especially when encapsulated within the metal shield.
In fact before this tool was available, I’ve heard of guys chipping away at the porcelain for several hours trying to get it out of the way so the 303-1203 could be used to remove the shield.
Sherwin :
Date: June 15, 2009 @ 10:11 pm
Does this tool work if just the ground shield is left in the head??
I’m in the middle of it right now for I’m halfway through changing plugs and one has broken off so far. HELP!!!
dennisb - Auto Tool Sales :
Date: June 15, 2009 @ 10:36 pm
Sherwin,
If you are saying that the electrode shield is left in the head and not the porcelain, then yes. You would just skip the step that pushes the porcelain. Good Luck
James :
Date: June 16, 2009 @ 9:29 pm
The lisle 65600 plug removal tool worked excellent on my 2006 F 150 w 5.4 ltr. It worked fantastic on the 4 broken plugs. It gave me confidence to complete the same job on a friends truck with the same problem.. All is well thanks James
dennisb - Auto Tool Sales :
Date: June 16, 2009 @ 9:32 pm
James,
Thanks for the feedback. Your friend owes you!
Sherwin :
Date: June 19, 2009 @ 9:05 pm
Got my tool yesterday and it worked fantastic! I’m back on the road again. Can’t say enough good about this tool it worked like a dream. Yes, I too can attest to the fact that this tool works. I removed four broken plugs in a half hour or less. I now would be able to do this job on any other Ford 3V with confidence.
Thanks a million!
Ken Hobbs :
Date: July 22, 2009 @ 11:41 pm
We used our new tool today and it worked just as designed. Slick! But I think the real winner is Champion’s one piece design sparkplug! I hope Ford can get over it’s”over-design-itus” and get back to good solid engineering. Don’t mention 6.0 powerstrokes!
Mike :
Date: July 25, 2009 @ 10:24 pm
THIS IS THE TOOL MOST FORD DEALERS ARE USING. IF YOU ARE MECHANICALLY INCLINED GET THIS TOOL AND DO IT YOURSELF. MY LOCAL FORD DEALER CHARGED ME 3 HRS LABOR TO REMOVE 2 BROKEN PLUGS. THEY USED THIS TOOL. I WAS WORRIED ABOUT HAVING PROBLEMS ETC… THIS TOOL IS THE WAY TO GO AND IT WORKS EASILY. DON’T BE CONCERNED ABOUT PUSHING THE PORCELIN IN. IT WILL STAY IN ONE PIECE. REPLACE YOUR PLUGS WITH THE CHAMPION ONE PIECE DESIGN AND THEY WILL NOT BREAK ON THE NEXT CHANGE.
MICK :
Date: July 28, 2009 @ 10:45 pm
Does the tool work if the porcelain breaks of above the jamb nut? Have you seen any cases where the tool doesn’t work?
dennisb - Auto Tool Sales :
Date: July 29, 2009 @ 6:20 am
Mick, it seems that the weakest point in the porcelain causes it to break in the same place (every time that I’m aware of). This tool has worked for everyone that we’ve dealt with that I’m aware of. Can it fail? Well anything is possible, but with as many pros & do-it-yourselfers tackling this job succesfully with this tool, I would say it’s definitely worth a shot (the last resort is removing the head). Also see our blog on changing Ford spark plugs in engines that use these plugs, the latest TSB is linked in that article. With patience and following the procedure, maybe the future spark plugs can be removed intact, eliminating the requirement of any extraction tools.
papa :
Date: August 1, 2009 @ 11:10 pm
I ve got your tool. And guess what the porcelain did break when i pushed it. And it falls in cylinder. I used a vacuum to suck the broken porcelain. But i dont think thats help. Now it looks like a misfire. And the truck sounds bad. Just let you know guys before you buy that tool. And now i have to remove the whole damn head…
The porcelain DID FREAKING BREAK. I removed 4 spark plug and all of them had broken porcelain (chipped in peaces).
dennisb - Auto Tool Sales :
Date: August 2, 2009 @ 8:33 am
Papa, I’m sorry to hear that you were not successful. Out of the hundreds of these tools sold, this is the first report of a failure. I can understand a few pieces of porcelain chips on the topside of the broken plug, before beginning the removal process.
I cannot imagine the porcelain falling into the cylinder if the tool is used as it is designed. After it is removed, I would look for any pieces on the bottom of the porcelain near the electrode. If it looks intact (like in the image below), then no pieces would have fallen.
You said “Now it looks like a misfire.” Assuming you were able to run the vehicle long enough (which is not advisable if there is an unusual top end noise) and if there is a misfire code set, like a P0301, P0302, P0303, P0304, P0305, P0306, P0307 or P0308 for a particular cylinder (one that had a broken plug removed). I would focus on that cylinder and verify the cause of the misfire. Possibly a cracked plug, bad coil, bad connection to injector etc.
You said “The porcelain DID BREAK. I removed 4 spark plug and all of them had broken porcelain (chipped in peaces).”
It’s not uncommon for the plugs to break upon removal, Ford has an updated removal procedure, we covered in a different repair blog – Changing Ford Spark Plugs. For others reading this, if removing plugs in a 3V valve engine like this, use the new procedure outlined in the TSB and hopefully no additional plugs will break.
The success of the Lisle 65600 is about 99.99 percent, but if anyone has doubts about using this tool after reading Papa’s comment, remember we do offer another alternative in the Calvan 39100 and Calvan 39200.
Regardless of which brand spark plug removal tool kit is used, either offer a very good chance of success and avoiding the last resort of removing the head.
Randy Martin :
Date: August 2, 2009 @ 9:18 am
After getting my plugs out I put Autolight plugs in only to find out that three cylinders misfired. The Ford dealer scoped it advised me to change to motorcraft plugs which they changed those three and it ran good for 150 miles then two different cylinders misfired. I just switched to the Champion brand (nice looking plug and never will break again!) and so far its fine.
john :
Date: August 2, 2009 @ 9:26 pm
I got 7 plugs out fairly easy but the 8th one seem to be doing fine to the point I reached in with a magnet like the rest and it didnt lift out, does that mean it is broken? As I am looking at your pic’s I can see how it my be possible.
dennisb - Auto Tool Sales :
Date: August 2, 2009 @ 9:32 pm
John, if the plug is broken the top part of the porcelain and the threaded part should lift out.
john :
Date: August 2, 2009 @ 9:36 pm
thats what I thought I’ve tired using needle nose plier s it doesn’t move but I can screw it back down in then back out still nothing have any idea?
john :
Date: August 2, 2009 @ 9:39 pm
with it screwed all the way up I doesn’t feel loose at the porcelain
M Owens :
Date: August 9, 2009 @ 9:02 pm
I have a 2004 F-150 with 5.4 24 valve engine.After my mechanic told me I would have to take my truck to ford to remove the plug I purchased the LIS65600 Lisle specialty tool and removed the plugs myself. Best money I ever spent I would recommend this tool to any Novice or professional.
Jerry H :
Date: August 10, 2009 @ 2:35 pm
I have a 2003 ford f150 with the triton 5.4 in it. The truck has 115,000 miles and runs like a top but i know that the plugs should be changed. They are still in because I am scared as hell to do this. The delaership said it would cost between 550 to 1500 if they had to raise the cab! I will never make this mistake again on a vehicle purchase! Will your tool work on the 2003 model?
dennisb - Auto Tool Sales :
Date: August 10, 2009 @ 3:40 pm
Jerry H, You may have the older style spark plugs used on the two valve engine (which had the blowout issue). The 2004 and up 3 valve engines are the ones that are prone to breaking when being removed.
Jerry H. :
Date: August 11, 2009 @ 3:08 pm
How do I determine if this is the case? And, is there a remedy such as a better plug with more threads?
dennisb - Auto Tool Sales :
Date: August 11, 2009 @ 4:54 pm
Vehicles Affected with the Potential Breaking Design:
Reference Number(s): 08-7-6, Date oflssue: April 18, 2008
200S-2008 Mustang; 2004-2008 F-lS0; 2004-2008 Expedition, F-Super Duty; 2006-
2008 Explorer, F-S3 Motorhome Chassis; 2007-2008 Explorer Sport Trac
LINCOLN: 200S-2008 Navigator; 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
So yours has to be the 2 valve (the type that could blow out). The threads are in the head (4-5), more threads on the spark plug wouldn’t help. Just keep in mind that if you have a spark plug blowout we have the best thread repair kit (Calvan 38900). You may never experience this problem though.
Pete :
Date: August 22, 2009 @ 7:48 pm
Ordered your tool just in case I needed it. Thank God I didn’t have to use it but it was a good feeling to know I had it if needed. Used Gumout carb cleaner after I broke the plugs loose. Let it set for 20 mins. Backed them out slowly. Had 1 stubborn one where I had to go over 30 ft lbs to get out. 2004 f150 fx4 38000 miles
dennisb - Auto Tool Sales :
Date: August 23, 2009 @ 9:21 am
Pete, More than likely would have broken at least one if you hadn’t been so careful! The TSB Ford finally came out with has really helped a lot.
dennisb - Auto Tool Sales :
Date: August 23, 2009 @ 9:27 am
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