I had a sudden loss of power along with shaking while driving on the interstate. Could not accelerate or even maintain speed on a upward climb. Managed to get home driving on back roads real slow. Used a code reader to see what's wrong and got an error code saying misfire on cylinder 7, so I went to change my spark plugs.
One of the boots broke as I removed it. Suggestions on how to get the rest of that boot off the plug are welcome.
Also noticed all but one boot have a bunched up seal between the boot and the coil pack. Is that something I should be worried about? Doesn't seem right to me. I'm wondering what could have caused this to happen. These were installed at a Ford dealership right around 80K miles. I now have 115K miles. They installed new plugs and boots. Could this be caused by faulty install or is this from heat? It kind of looks like warping from heat.

I can install new boots and plugs no problem, but I want to know how this might have happened so I can deal with anything else that could be wrong.


Broken boot on left also has a bunched up flange. between the boot and the coil pack. The one on the right is the only one not like this.

 

The bunched up boot looks like install error, that's not a material or part that would shrink like that due to heat. Some guy in a hurry jamming the parts in.

Did you get the plugs out yet? Wouldn't be a surprise to find problems there too. I'd show those seals to the service manager at the shop that did the work. He probably already knows though.

 

I already called the service manager and he said since it's been 4 years it doesn't matter if they screwed up or not, they won't cover it. I could try to convince him otherwise, but it might be best for me to eat the cost since it's not that bad. It's just not worth the hassle and my temper goes from zero to nuke in a hurry when I'm dealing with people like that.
I haven't taken the plugs out yet. I have the replacements ready but I need to get that broken boot out first.

 

Were it me I'd use a pick. Get a good one, the cheap ones can fall apart.

 

Happened to me. Use long handled needle nose pliers and flashlight to gently pull out the remains. Before you remove the spark plug, hit it with compressed air at bottom of chamber to blow out any remaining bits. I had to mangle mine into pieces to get it out. It wasn't that difficult.

They pull off easier with a warm engine, and when you re install use a bit of dielectric grease where the rubber slips over the spark plug porcelain.

 

I was really hoping I could get out of this without spending too much, but if I have to replace all these it's going to cost me over $400 at RockAuto. That's for 8 Motorcraft Ignition Coil DG-542. I thought this was two pieces but it appears to be all together with the coil. Am I wrong?

 

coil packs are sold with the boot installed already.

Denso either makes ford/motorcraft or is made by them, I believe last time around I went with Denso and theyve been fine incase they're a tad cheaper

I would try spraying some PB Blaster or something inside the remainder of the boot and let it soak then get some really long needle nose pliers and say a prayer

 

A thought, from removing stuck hoses - run a long thin pick or skinny screwdriver around the outside of the boot and the valve cover hole, and around the inside of the boot and the plug porcelain. Break the bond there and it should be easier to pull out.

Not so sure about PB Blaster or other lubricants. Makes the boot material harder to grab hold of especially if it swells it. Depends on your tools.

 

Am guessing you don’t need new coils. They look different but these boots were available for my 3.5l from the dealer. Coil pictured is original OEM.

 

Good to know. I'll take another look at mine to see if I can get the boot off. I think I will buy one coil for the cylinder that was misfiring. Might be overkill but I don't have time for this to happen again. I just don't want to buy 8 coils if I don't have to.