THIS IS THE VERY BEST IN FORD SPARK PLUG THREAD REPAIR KITS. You DO NOT have to remove the head for this repair. Link back to: Ford spark plug repair kit page p/n
Their are 2 different issues to address: Valvetrain components were lightened as much as possible, including the use of sodium filled exhaust valves, while strengthened powdered metal rods and forged aluminum pistons were added. My own personal opinion is that waiting until , miles is asking for trouble and I believe waiting that long contributes to these spark plug problems.
Also the cylinder head is aluminum, the spark plug has steel and other components and the 2 dissimilar metals will lead to corrosion. The other thing that leads to these breaking off is that the OE spark plug is a 2 piece design and you can see from the images below the difference.Revised video on CalVan inserts on Ford Triton 2 valve engines
Champion makes a spark plug that is 1 piece and while you should always try to put OE back on, In this case you may want to consider switching to Champion for their 1 piece design.
So with all of that said, If you change your plugs at 30K intervals, you have a much better chance of avoiding the plugs breaking and you may even prolong the life of your ignition coils too.
Recommended steps to try and remove plugs without breaking them: I do a full tune up on my own truck at 30, miles. Let the vehicle cool, Ford specifically calls out in their TSB to allow the engine to fully cool and do not attempt spark plug removal on a hot engine.
A high quality penetrating oil should be used next like Aerokroil or PB-Blaster 3. Use premium good quality tools that allow you to get a good solid strong and square position on each spark plug.The other thing that leads to these breaking off is that the OE spark plug is a 2 piece design and you can see from the images below the difference. Champion makes a spark plug that is 1 piece and while you should always try to put OE back on, In this case you may want to consider switching to Champion for their 1 piece design. Valvetrain components were lightened as much as possible, including the use of sodium filled exhaust valves, while strengthened powdered metal rods and forged aluminum pistons were added. We see most trucks coming in with a misfire problem at around 60,, miles.
The passenger side of the engine is where most breakage occurs so pay special attention their. If a spark plug breaks and it usually will if you wait until K, then you will need one of these kits to remove the rest of it from the cylinder head.
I have used the Lisle and it worked like a charm and it only took about 15 minutes. Dorman is similar, however I have not yet used that one and cannot say how it works but lots of them sell.How to Remove a Broken Spark Plug in a Ford Triton
Spark plugs are loose or actually blow right out of the cylinder head and typically strip or pull the threads out with them. I am somewhat of a Ford person and am not here to bash Ford, however I would like to clarify what happens in this situation.
When a plug is loose and an engine is rotating at rpm, it generates a tremendous amount of pressure each time it fires a cylinder. So the longer a spark plug wobbles from being loose in the threads the more thread damage it does and finally the last few good threads can no longer take the pressure and out comes the plug!!
So here we are and what do we do now? Most troubling to me is the huge diversity of dollar cost and repair procedures for a relatively simple thing to fix.Cal-Van Tools Triton Spark Plug Thread Repair Kit for Ford is the kit that the professionals choose to fix this issue on Ford Triton engines. The patented insert is oversized, heavy-duty and can be used to replace previously installed inserts that have failed.
A thirty dollar HeliCoil kit can do the trick if installed correctly with a good loctite compound installed on the threads of the repair insert. Sadly most mechanics just re-tap the hole and throw an insert in and a new plug.Repair A Blown Out Spark Plug Ford 4.6 5.4 6.8 Triton Engine
It usually lasts a while and then blows again creating a bigger problem! As the mechanic indicated above, an inexpensive HeliCoil kit will usually do the trick — but not always permanently. Just make sure to have the work evaluated and done by a trusted mechanic.