Spark Plugs May be Difficult to Remove on Ford F-350 Super Duty

Our technicians tell us the spark plugs in these engines can be very difficult to remove. Ford has issued a service bulletin (08-7-6) to address this issue, which includes a recommended procedure on how to remove the plugs. Failure to follow the recommended procedure can result in the one or more spark plugs breaking off in the cylinder head.

The recommend procedure is as follows. Using this procedure will greatly reduce the chance of breaking a spark plug.

1. Break the spark plugs loose when the engine is warm.
2. Turn each plug 1/8 to 1/4 turn and soak the treads with 1/2 to 3/4 teaspoon of Motorcraft Carburetor Tune-Up Cleaner or a quality penetrating oil. Do not try to remove the plugs at this time.
3. Let the threads soak for at least 15 minutes.
4. After the soak period, tighten and loosen each spark plug, working it back and forth until the turning effort is reduced. Then, you can remove the spark plug.

There are special tools available to remove the broken spark plugs and repair shops will often charge additional labor time, over and above the quoted spark plug replacement cost, for the removal of each broken spark plug.

RepairPal Verified
Average mileage: 75,516 (75,516–75,516)
Engines affected: 5.4L V8, Gasoline
4 model years affected: 2005, 2006, 2007, 2008 more
5 people reported this problem
1 person shared problem details
2006 Ford F-350 Super Duty- 5.4L V875,516
Sheared the #1plug on the left bank. Apparently there had already been a severe fracture on the factory installed plug. The #1 plug sheared below the socket connection and halfway down on the threads. Issue is still being addressed on whether the old plug section that is fused to the head can be removed or if the head MUST come off!!! Will never allow this issue to happen to me again!!!
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