R&TBabich

Your plugs and AC are separate issues.
The AC is going to be expensive, I just had the compressor replaced on our Exped, be sure to get the truck version of the compressor if yours came with it OEM.
For your plug issue, hopefully the fuel injectors were disconnected, which seems likely because if the CATs were clogged you wouldn't able to accelerate fast or go over 40 mph or so.
Whatever is in there needs to be pulled and a compression test done on those cylinders.
If the compression is good you may be able to get inserts installed to repair the threads.
The guys at Timesert may be able recommend a method to repair the threads once you find out what is in there.

01-7700

FordTechMakuLoco makes it look easy with this kit CalVan Tools 38900

with the head still on the engine.

97XLT4x4longbed

my wife’s stepfather has been a ford mechanic for decades and he basically just covers evreything up and does the bigserts on any Triton that throws the plug. Cost the insert (~100$) amd your own labor. Getting this truck we were ready to basically have to do it plus a few other known issues (especially sitting so long)

texan_176

I tinkered with the truck after work today. Just to see if the a/c and coils are related I plugged in the 2 coils on #4 and #6 without even seating the coils in position. I started the engine and the a/c instantly works; ice cold too like it was before this job. The ECM absolutely looks to see if all coils are present before allowing the additional load of a/c use. This was a huge relief.

I called a local Ford specialist and he wants $150 to examine the engine and determine if he can fix it. The way he was talking I will be looking at $500-1000 when it is all said and done; vibes were not good with this guy. Now I am leaning towards buying the CalVan kit and a cheap scope to look inside the cylinder to DIY #6 since access is really good on it. The tool reviews say it is impossible to screw it up. A little research tells me what I have in the engine are temporary plugs so it should be fixable meaning there is enough material left in the bore to tap it. The #4 cyl will be a PITA. I don't see how it can be done without the intake manifold coming off. The truck has been running okay for what it cost on 6 cylinders. If I bring #6 back from the dead ($300ish in tools) maybe it makes sense to just run on 7 cylinders instead of opening a can of worms by trying to fix #4.

It's stunning Ford screwed up these and the 3 valve engines so badly considering their decades of R&D know how. I would expect this of some start up car maker with limited resources.

texan_176

Thanks for the video. I saw that a few days ago. He makes it look way too easy. If he were local I would just hire him for the job and be done with it.

Just to change the plugs on #7 and #8 is a PITA.

BareBonesXL

Are you going to show those bolts are not?

texan_176

97XLT4x4longbed

fordguy2100

If you torque them properly and don't use anti-seize you aren't going to blow a plug. 28 ft/lbs DRY is the updated torque for spark plugs.

white89gt

I'm not too certain in what instance this "temporary plug" would be deemed necessary. They cost 50 bucks a piece on Amazon. Might as well fix it right to begin with. Sure.... maybe breaking down a long way from home I could see using it to JUST get back home, but who the hell is going to have one of these with them out on the road? Just seems like it might be the dumbest band-aid I've seen.

So, OP.... you never answered us.... was your truck running sans spark plugs, with the injectors still firing?