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

See the quality difference in the Heli-Coil (top) & the Calvan (bottom)

In this automotive repair/tool blog we cover Ford spark plugs blown out of cylinder heads, it’s still a huge problem. To date we have sold hundreds of Calvan spark plug thread insert tool kits and have had no one call back to say it was too hard or it didn’t work. The included video makes the spark plug insert repair easy to understand and answers all the questions about how this job can be done in the vehicle saving thousands of dollars. We are commonly asked if the Calvan spark plug repair kit will work after TimeSert, Heli-Coil or some other thin, weak repair has failed and have blown out AGAIN. The answer is yes, Calvan inserts are much thicker than the competitor’s inserts and will work much like an over-size oil drain plug will work in a stripped out oil pan. Since the Calvan insert is not just a coil of wire like the Heli-Coil it is much stronger. And since the Calvan insert is thicker than the Time Sert, many times it can be used when the Time Sert is spit out.

Tags: time, sert, ford, spark, plug, blowout, spit, auto, automotive, repair, tool, triton, 4.6, 5.4, 6.8, insert

OK, finally Calvan has released their version of the OTC 303-1203. The Calvan is pictured on the left and the Rotunda is on the right. Calvan actually did a very nice job, improving on the Ford design and including a storage case. And they even upgraded the thread tap by adding badly needed length to it to reach down in the spark plug recess of the cylinder head. Still no word about if Calvan is going to tackle the production of a lower cost equivelant to the 303-1398 porcelain remover. We can special order the 303-1398, but with the price around $700 we have refused to stock them. Hopefully someone will figure out an easier, less expensive way to remove the porcelain without the over-priced Rotunda 303-1398. Early TSB’s from Ford said to remove the porcelain with needle nose vice grips. I’ve also talked to tech’s that chip away at the porcelain until it can be removed piece by piece. Mustangs, F150’s, Vans and Rv’s are affected, any Ford with a 4.6 or 5.4 could have this problem. If anyone has found an effective way to remove the porcelain, please comment. At least now we have a nice alternative in the Calvan 39100 to the Rotunda 303-1203.