4.Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a.Install the stepped end of the tool pilot bushing into the spark plug
well ensuring it bottoms out.
b.Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping.
c.Install the nylon washer and jack nut until finger tight.
d.Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly.
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1.Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2.Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain.
3.Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head.
Mode 3 Procedure:
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE.
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING.
1.Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2.Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can.
3.Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
4.Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5.Insert the completed assembly into the spark plug
well and fully engage the pin into the porcelain. (Figure 15)
6.Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug
well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin.
7.Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16).
8.Repeat Steps 6 and 7.
9.Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug
well and porcelain with dry compressed air.
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10.Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11.Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air.
Porcelain Removal - Bonding Process
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD.
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1.Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17)
2.Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3.Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4.Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure.
5.Reassemble a dry and clean collet and pin assembly.
6.Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin.
7.Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8.Insert the completed assembly into spark plug
well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent.
9.Add additional Loctite® 638TM, repeating Steps 6-8.
10.Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED.
11.Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12.Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1.After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod.
2.Install the washer and jack nut until finger tight against the tool pilot bushing.
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3.While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode.
4.Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head.
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated.
Key elements to success are:
^Clean and dry porcelain
^Sufficient Loctite® 638TM Retaining Compound spread uniformly
^Loctite(R) 638(TM) cure time and temperature
^Preventing the threaded rod from rotating while removing the porcelain
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIMEMT080706 Claim Labor As Actual Actual Time Time
DEALER CODINGCONDITION BASIC PART NO.CODE1240501