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Old 03-29-2015, 01:06 AM   #1
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Anyone change plugs in a 5.4 Ford 3 valve engine?

I just did! Lots of issues with it but its not that bad a job

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Old 03-29-2015, 04:42 AM   #2
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Dreading doing that job on my 6.2... They have 16 plugs instead of 8...

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Old 03-30-2015, 12:14 AM   #3
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Did you break any? If you de-carb the engine by drowning it in SeaFoam and letting it sit for 20 minutes before you change them you can avoid breaking them. The threads stick in so far that they get clogged with carbon and then do not want to come out. Did you get one piece plugs this time?
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Old 03-30-2015, 06:06 AM   #4
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Run a product like Liquid Wrench or a decarbonizer through their fuel tank for a day or two. You could also use Yamaha Ringfree Plus in the tank for awhile--a decarbonizer.
Drive the truck until the engine heats up.
Remove the coils (on the spark plugs,) and soak PB Blaster or other penetrating oils into the spark plug holes--letting them sit overnight.
Use a long extension, 1/2" drive long nose socket and strong impact wrench to remove the spark plugs.
Be prepared to buy the Lisle spark plug removal tool if you break any plugs.
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Old 03-30-2015, 10:28 AM   #5
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Many of the techs are using battery operated impacts to remove the spark plugs. The attached .pdf explains a lot. I wish I could give credit to the tech that made this document but I found it on a Ford Forum site and do not have the authors name.
Attached Files
File Type: pdf Ford Spark Plugs.pdf (1.70 MB, 99 views)
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Old 03-30-2015, 11:22 AM   #6
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Old 03-30-2015, 11:42 PM   #7
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Had the removal tool before I started .
Followed the Ford TSB. Cold, cracked them 1/4 turn and soaked overnight in PB. Went 7 for 8. Only broke 1 and it was #6, very easy to get to and it broke only the shell. The porcelain came out in 1 piece. Had 98,000 miles on them. Won't go that long again. 60K - 70K and I'll change them again. It was farting and bucking before I changed them.
Cleaned everything up with Brake Clean and air blasts to remove all the PB down the hole (plugged the spark plug holes first). Replaced the rubber boots, applied nickle anti seize to the plug nose and torqued to 25 ft lbs.
If anyone does it, you can feel if it breaks before it comes out. If it squeaks and comes out tight (30 ft lbs) all the way it is in good shape. If it turns 1 or 2 turns and then comes easy it broke.
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Old 03-30-2015, 11:47 PM   #8
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Forgot to add I ran 2 tanks fulls of Seafoam before I did it. It probably helped. Runs like a Swiss watch now. Smooth.
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Old 03-31-2015, 06:10 PM   #9
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Running the Seafoam through helps a lot and even better if you suck it up through the brake booster vacuum line until it stops the motor. Then let it sit for 20 minutes or longer then run it until the smoke clears. No more carbon and no mosquitos for a couple blocks around you either, ha ha. Really smokes!

The impact driver really does help also.
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Old 04-04-2015, 10:39 PM   #10
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Not all years of 5.4 engines are affected. I can't remember the years but it's the ones with the 2 piece plugs. Google it to find the years affected.
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Old 04-04-2015, 11:52 PM   #11
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I had never heard of this...wow looks like a train wreck looking for a place to happen.
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Old 04-05-2015, 05:01 AM   #12
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The good news is that Ford changed the plug and head design starting with the 11/30/07 engine build date, correcting the issue. So basically, if you have a 2008 or newer engine, this should not be a problem.

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