Report: Spark Plugs May be Difficult to Remove
Ford Expedition Problem
Average Mileage: 74,700 mi (9,100 mi - 110,000 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.
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
Visitor, 2007 Ford Expedition, 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.
Visitor, 2006 Ford Expedition, 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!
Visitor, 2006 Ford Expedition
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