Changing Ford Spark Plugs 4.6, 5.4, 6.8 – Ford TSB 08-7-6
July 25, 2009 12:35 pm Auto Tool Comparison, Automotive Specialty Tools, Calvan Specialty Tools, How To Auto Repair
Unique Ford spark plug design can easily break when removed
When changing Ford spark plugs it’s good to be aware of the potential of breaking them in certain models. In this repair article, find out which ones are susceptible to separating when being removed. Learn how to remove them without breaking them and how to remove them if they do break. Denlors Auto Repair blog has had several articles about removing broken sparkplugs in Ford vehicles. In addition to Rotunda Separated Spark Plug Remover, we offer several less expensive options of removal tools. Compared to Ford Rotunda special service tools, we save our customers a lot of money, when removing broken spark plugs.
Which Ones To Look Out For
Affected vehicles include; 4.6, 5.4 and 6.8 3V engines found in many 2004-2008 Ford Mustangs, Expeditions, F150’s, Motor-homes, Explorer Sport Trac, Mercury Mountaineers, Lincoln Navigators and the Lincoln Mark LT. Ford has recently came out with a new TSB that supersedes the first ones, that may prevent breaking the sparkplugs to begin with. We have included TSB links towards the bottom of this repair article, courtesy of the Ford Motor Company.
The Short Version
The updated procedure consists of 7 pages (see the PDF links below) basically says to back the sparkplugs no more than 1/8″ to 1/4″ of a turn. Then use a small amount of carburetor cleaner in the sparkplug well and allow time for the cleaner to make it’s way down to the electrode shield. The idea is to loosen the carbon buildup around the electrode shield to allow sparkplug to be removed without breaking it. The process may need to be repeated several times in order for it to work properly. Furthermore the TSB states that a torque wrench must be used to prevent excess pressure from being applied when working the spark-plug back and forth. If the torque exceeds 33 foot-pounds, the porcelain could break. Caution is also advised to prevent the possibility of putting too much carburetor spray down the well, if this is done excessively the engine can become hydro-locked. I can only imagine the frustration involved in trying to remove these wacky sparkplugs and then ending up with a hydro-locked engine!
How’d That Work Out?
So what happens if the TSB 08-7-6 procedure has been followed when changing the spark plugs and a sparkplug still breaks? As mentioned before we have several options for removing Ford sparkplugs when they break. The first alternative to the Ford rotunda sparkplug removal tool (303-1203) is the Calvan (CAL 39100 – ET391). This tool is basically a copy of the Rotunda 303-1203 at a much lower cost. This tool is used the same as the 303-1203. It can only be used if the porcelain did not stay inside the electrode shield. The porcelain must be removed first to use either of these tools. Ford’s method uses a 303-1398, the Calvan equivalent is the CAL39200. This approach uses pins that are lock-tighted into the center of the porcelain where the electrode pin was. After the Loctite dries a puller is used to remove the broken porcelain.
Lisle Method
Another option is the Lisle 65600 Ford broken spark plug remover. We’ve done an entire auto repair article featuring this tool and it’s different method of dealing with broken spark plug porcelain. That particular repair blog, includes pictures of the tool in use. Also there are some testimonials from guys that used the Lisle tool. Whichever method is used, it’s still a lot better than removing the cylinder head. Hopefully with the new procedure, removing the spark plugs intact may be possible and no specialty tools will be needed to begin with.
Ford TSB for Spark Plug Removal – see all 7 pages below.
Ford TSB 08-7-6 Page 1 Ford TSB 08-7-6 Page 2 Ford TSB 08-7-6 Page 3
Ford TSB 08-7-6 Page 4 Ford TSB 08-7-6 Page 5 Ford TSB 08-7-6 Page 6
More TSB’s can be accessed on-line along with detailed repair information. Use the instructions needed now and log back in for other repair projects at a later date, all for ONE low fee. Visit Mitchell’s eAuto Repair, access the same repair data Mitchell provides professional shops everywhere.
dennisb - Auto Tool Sales :
Date: October 30, 2009 @ 7:12 am
If you haven’t already, see our related articles on Broken spark plug removal and the one on the new Champion one piece design plug.