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

 Ford TSB 08-7-6 Page 7

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.

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Tags: Changing, Ford, Spark, Plugs, 4.6, 5.4, 6.8, Ford, TSB, 08-7-6

Video inspection scopes are now quite affordable.

Doctors have used fiber optic bore-scopes and endoscopes in the medical field for a longer period of time than automotive technicians have used inspection scopes in the automotive repair field. The high cost for these gadgets in the past prevented lower income fields from justifying the purchase of them. 

Like with many technology driven items, the cost of these useful tools has came down since their introduction. The lower cost, first on fiber optic borescopes and now more recently on video based inspection scopes has opened the market up and made the purchase of inspection scopes more feasible for other markets besides the medical field.    

The fiber optic borescope was once the only specialty tool of it’s type made for automotive and other inspections that require access to very tight areas. Using fiber optic boresopes can be a little awkward though. The small eyepiece on most fiberoptic borescopes require your eye to be positioned at just the right distance from the view finder to view the object. In addition, the distance from the wand to the subject and manual focusing is must be adjusted to view properly.

Video based inspection scope prices have came down to a very affordable range and are are easier to use compared to fiber optic borescopes. Most video inspection scopes have color monitors, not just a small eyepiece for viewing. Most video inspection scopes have an automatic focus feature instead of the manual focus found on fiberoptic borescopes. Image quality is superior in comparison and can be viewed by several people at the same time. Some video based scopes allow the capability to transfer still images and video to a lap top computer. Once saved as a file on the computer, the footage can be shared easily with clients if desired. This is sure to become a standard practice for after market extended car warranty companies. Auto warranty Inspectors can email their car inspection video to the warranty company as easily as they now send jpegs.

If considering the purchase of an inspection scope, then a video based inspection scope is worth a look (no pun intended).

Tags: bore, scope, endoscope, Fiber, Optic, fiberoptic, Borescopes, Video, Inspection, Scopes, auto, automotive, specialty, tool

Good – Simple Actron Code Reader CP9125

The CP9125 Actron code reader is a very popular choice for the DIY (Do it Yourself-er) and for many used car dealers that want to read codes before the auction (or clear the codes prior to their car being ran through). The size of this tool makes it easy to carry in your pocket. No frills, just a good basic code reader with about 3,000 definitions for Global OBD 2 codes. This code reader works on all cars with US emissions, OBD II connector 1996 and up.

Better – Code Reader with Definitions

The Launch CReader is a basic OBD2 code reader that is great for the DIY (Do it Yourself-er) or the auto mechanic that would like to have the convenience of reading and clearing Power Train Codes, without the expense of owning a more elaborate scan tool. The Launch CReader is also capable of working on vehicles with CAN protocol. Controller-Area-Network, or CAN-bus is a new computer network standard that enables multiple control modules to communicate with each other. To illustrate how great a deal this is, consider this; The CAN adapter alone for a Snap On MT2500 Scan Tool is around $250. Without it the Snap On Scanner is unable to communicate with many vehicles. The Launch CReader also allows Freeze Frame Data to be stored and viewed. Freeze Frame Data means that at the time the CEL (Check Engine Light) comes on, sensor readings are recorded. This can be very helpful in cases where a sensor may have an intermittent failure and then be functioning as normal when the diagnoses is attempted. Having Freeze Frame Data with an inexpensive code reader is a real plus. Another useful feature the Launch CReader has is the built in Readiness Monitor. The Readiness Monitor will let let you know when a drive cycle is complete after a repair has been made. Since many conditions have to be met to complete the drive cycle, this indicator takes out the guess work. A Readiness Monitor alone, that indicates when a drive cycle is drive is complete can be priced over a hundred dollars.

Good – Actron CP9190 Scanner Graphs & is Bi-Lingual

The Actron CP9190 scanner has the features of the CP9125 and more. The Actron CP9190 has graphing and printing capability. This scanner in addition to scanning OBDII and CAN protocol vehicles has cables for some OBD I vehicles. So in certain cases this scanner could be more useful especially if your first language is Spanish or if you have a classic (or a work car) in the garage that has OBDI. The larger back lit display is easy to read and this scanner has it’s own batteries that allows the code information to be displayed even after the OBD interface cable has been unplugged.

Better – The OTC 3499 has more enhanced codes

The OTC 3499 Scanner has more enhanced codes including codes for Honda. OTC is one of the largest manufacturers of automotive scan tools, OTC actually owns Actron as well. Actron is tailored to the DIY (Do it Yourself-er) and OTC is marketed more to the professional auto Technician. Also Bi-lingual, the OTC 3499 has a larger display than Actron and also has extra interface cables enabling it’s use to a wider coverage of vehicles in addition to OBD II, it includes OBD I connections for GM, Ford and Chrysler. 

Tags: Automotive, code, reader, auto, specialty, diagnostic, tool, Scanner, Review

The Rigid brand video inspection scope is called the SeeSnake 

Rigid Micro SeeSnake is an option with a 3 foot reach, a magnet and clip on mirror included. The main drawback with this tool is that the camera at the end of the wand is 0.70″ and that prevents the use of this tool in smaller areas like in an engine’s cylinder through a spark plug hole. A better size for the probe on borescopes and video endoscopes is under 0.50″ this allows access to much tighter areas. The Micro SeeSnake inspection camera has a 2.4″ color LCD screen that has 160 x 234 resolution.

The Visual Optics brand inspection scope is called the Video Stik 

The Visual Optics video inspection tool is called the Video Stik, Visual Optics’ inspection scopes come in 36″ or 72″ and are made in the USA. The Video Stik with it’s 320x 240 pixel resolution, provides a more defined image compared to the Rigid SeeSnake with it’s 160 x 234 resolution. The camera on the end of the wand is smaller too. Compared to the Rigid brand that has 0.70″ diameter, the Video Stik has a 0.42″ diameter, allowing access to more spaces. The Visual Optics Video Stik also comes with accessories. The magnet an mirror are small enough to access very tight areas, after-all if they don’t fit into the area needed they are useless.

Automatic Focus allows for ease of use when compared to fiber optic borescopes. Fiberoptic bore scopes were at one time the only game in town when it came to affordable inspection scopes. New technology in affordable video based inspection scopes has changed this forever. New electronic gadgets like these, are sure to spawn more competition in the new Affordable Inspection Tool Arena, DLT’s top pick for automotive inspection is the Video Stik.

Tags: Video, inspection, scopes, borescopes, rigid, seesnake, stik, bore-scope, tools, auto, automotive, comparison