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Ford Spark Plug Removal Tool – Picture of Ford’s Bad Design

10:44 am Auto Specialty Tools, Consumer, Ford Problems, Lisle Specialty Tools


If  Ford’s poorly designed spark plugs would just all come out like these.

© Lisle Spark Plug Extractor DLT  Summary: 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.

Rest of this post including a link for the instructions & Youtube video on page 2 –

Continued on  the next page.

Buy the Lisle 65600 now.

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106 Responses
  1. Archie :

    Date: November 26, 2015 @ 5:53 pm

    All eight plugs broke during removal on my 2006 Mark LT. Anticipating this, ordered the Lisle
    65600. Pushing the porcelain is my only fear. All have left behind the ground electrode shield. 6 of the plugs left behind empty electrode shields with the porcelain. Any suggestion on using the new Lisle extractor when resuming the work.
    Thank you for being detailed and helpful in advance!

  2. dennisb - Auto Tool Sales :

    Date: November 27, 2015 @ 9:49 am

    Archie, I would have done one at a time instead of breaking all 8 first. I would have had suggestions for trying not to break them to begin with, but what’s done is done. I would at this point follow the instructions. Keep in mind we have replacement puller screws. They are a wear item that may need to be replaced, especially since you’re doing all eight. Good Luck.

  3. Archie :

    Date: December 4, 2015 @ 1:52 pm

    I was successful with all eight broken plug extractions. Truck is now running but cuts out completely when attempting to accelerate. It acts like a fuel problem – idles poorly, and gives me nothing when in gear. I appreciate any help you can provide.
    Thank you,

  4. dennisb - Auto Tool Sales :

    Date: December 4, 2015 @ 1:58 pm

    Fuel pressure reading? Vacuum leaks. Codes… Good Luck

  5. Mke :

    Date: April 21, 2017 @ 12:40 am

    Hey Guys, I have a Ford 2005 Expedition 5.4. In Oct 2016 cyl. #2 showed misfire code. I replaced plug (rusty) eventually found leak in the heater hose control valve right above cyl. #2. Next code on #4 replaced using Lisle. Tough area great tool. This month had some time so decided that I would replace the rest, no codes but you know the drill on these Tritons rough lower gear shifting etc. So.. 2 plugs a day first 5 all broke a little extra twist to complete the separation and all came out looking like syringes. Good job. Lisle pulled the nose cone great on all. #3cyl. though right now still has entire length of the electrode and at first all the ceramic intact without the nut casing. The top stem broke while trying to use the needle nose pliers to get the remaining plug out. It is extremely tight. What should I try? J/B weld the nut collar back on and try again to break the ceramic at the nose ? Or J/B weld a steel tube to the electrode to try to twist it out and then possibly bore out the ceramic down to the top of the nosecone? Whew! Thanks, Mike

  6. dennisb - Auto Tool Sales :

    Date: April 21, 2017 @ 7:25 am

    Mike, JB Weld is good but I don’t think it’s going to help in this situation. I’d try the Lisle Porcelain Puller which is included in the Lisle 65700 kit. Also, for others reading this we now have the OTC 6918 that grips the plug assembly keeping it together so that it can be removed without breaking it to begin with.

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