Car Problem Reports

Ford Expedition Spark Plugs May be Difficult to Remove

Ford Expedition Problem
16 Reports
Me Too

Model Years Affected: 2005, 2006, 2007, 2008

Average Mileage: 112,178 mi (73,250 mi - 175,000 mi)


Our technicians tell us the spark plugs in this engine 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.

  • Visitor, , 73,250 mi

    Miss in engine at WOT. Took vehicle into dealer to get spark plugs replaced.
    Had to pay for a fuel injector clean to remove carbon deposits that lock the spark plugs in.

    Did not work, 7 of 8 plugs broke and had to be removed.

    Over $1000 to replace spark plugs, way to go ford!

    Flag This
  •  Rookie

    I took my Expedition to a local mechanic and he broke off the #3 spark plug then called me telling me he didn't know what to do. After researching this issue i found that this is a know problem to ford so I had it towed to the dealership. They were able to remove the broken plug, plus the other 7 without any further issues. It took them a few days to get to it so I had no choice but to rent a car. So a $300 job ended up costing me $1000.00

    Flag This
  • Visitor, , 90,000 mi

    Brand new plugs from motorcraft are breaking. Ford need to agrees this. Cost more just to have them decarb. Many ford dealers state that either they charge for extra service or if not they will charge for for extra labor for each plug that breaks off.

    Flag This
  • A special tool had to be used to remove the broken spark plugs from my engine.

    Flag This
  • Visitor, , 105,000 mi

    After letting penetrating oil soak overnight, 6 of the 8 plugs broke off in the engine. Special tool did a great job at removing them.

    Flag This
  • Visitor, , 175,000 mi

    Chugging and misfire at about 50 MPH at slight acceleration changes. Not fixed - living with it.

    Flag This
  • Visitor, , 90,000 mi

    Buy extractor tool if diy before start.

    Flag This
  • Visitor, , 110,000 mi

    hesitates and lunges at 40 mph. check engine light came on and computer read misfire on coil 1. Replacing spark plugs but difficult to remove. hoping this works!

    Flag This
  • my truck kept cutting off on me and displaying engine light took it to the shop and i had to pay $100 for each spark plug to be removed then i had to pay them to pyt them back in.....terrible terrible expereince i ended up paying over $1000 juz for a tune up

    Flag This