I have a '05 ford f-150 that was due for a spark plug change,I used a proper spark plug socket (otc part #6900). When I removed the front passenger side plug, the plug came out, but the unusually long spark plug electrode is still stuck in the head. I tried to use some spray to loosen it and a small e-z out, but it won't budge. Any one else have this problem, does the head have to come off to get it out ??? Any help will be appreciated.

 

ther are acouple of tsb's on this it is along process to get them out that you have to do they break then you have to remove heads or i think there is a tool you can by do a search on it you should find the info needed

 

Do the search, its a long list. Have never done it, in fact don't own a v-8 with the problem. Basically after getting out the plug, a Heli-coil is inserted to repair the thread. We used Heli-coils back in the 60's on aircraft and engines. Its a proven repair and meets the standards of the FAA for Aircraft. Hopefully others will chime in, am sure I ruffled feathers.

 

You really need to find the TSB and follow it. If you do you may have good luck but you may not even still. If you are not prepared to tackle the task take it to the dealer but be prepared to shell out some cash if they break at the dealer and they have to pull them out with their special tool.

 

Sorry to hear you've been hit by the dang plug. This is a well known issue, due to a poorly designed plug. Ford does had a tool for removal and a new plug design that came out in late '07 I believe.

I need to find the documentation on another site I frequent, so I'll post up either this evening or in the morning when I find it.

Here's what the plugs look like when they break off in the head.

http://s50.photobucket.com/albums/f3...sparkplugs.jpg

 

Thanks for your help guys,but I talked to my local ford dealer , and I think I'll just have them take care of it. This will be the first time I've had to take my truck in since it was new. My sister works for a lincoln dealership in Jersey,I'll try to find out the tool # from her and will post it to try help anyone else as soon as I can.

 

is the pocelin part or the medal part in the head still? I have a tool that I think can save some time if it's just the medal part. I've got some small mechanical fingers that will fit down inside the hole then when almost to the bottom of the electrode, open the fingers, wrap around the bottom, and release the plunger, then lift up on the plunger pulling the electrode up out of the hole.
another option would be to push thin rope into the hole filling it up (the same way you'd do valve stem seal replacement) after the hole is filled up, then you roll the motor over and the rope hits the bottom of the electrode pushing it out of the head.

 

how often do spark plugs need to be changed?

 

They are rated for 100k miles, but most change them out well before that to hopefully avoid the breaking issue. The longer you leave them in the more carbon buildup you're going to get. I'm at a tad over 36 miles right now and thinking about doing mine.