Spark Plugs May be Difficult to Remove on Ford Expedition

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.

RepairPal Verified
Average mileage: 119,955 (73,250–182,000)
Engines affected: 4.6L V8, 5.4L V8
5 model years affected: 1997, 2005, 2006, 2007, more2008
22 people reported this problem
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Viewing 1 - 15 of 15 problem details
2006 Ford Expedition 125,000 mi,
Plugs are ridiculous!! I challenge the average consumer to try and remove them even according to the instructions on here..MY ASS!!.. What a piece of crap design!. Should be recalled!!.. Try getting tool to remove them!..250$!.. What the hell!.. Resorting to driving on 7cylinders for past 3 months!!. Mine was the limited edition.. Very expensive!! Only thing limited are my funds to fix its plugs! Come on ford! Stand behind your mistakes and I will stand behind you!.. Currently own 4 fords.. Things are going to change to Chevy country around here.. Shouldn't have to pay garage 6 to 700 for new plugs...and I supply the plugs.. Still have those plugs!. Send me a tech Ford.. Tearing up my 40,000 $ SUV new, pretty damn quick on 7 cyl. Family vehicle???? Not yet !. No vacation this year kids..have to spend our budget on 700 sparkplugs in order to go!!! My number is 2172736003 if anybody out there has any kind of pull!!!.
2007 Ford Expedition 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!
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
2007 Ford Expedition 182,000 mi,
My 2007 Expedition was jerking and acting like it was going to shut off when I stopped. I changed #1 ignition coil and it ran great for a few days, then back to the same problem. We are about to have spark plugs changed. Glad I read these post so I know ahead of time what to look for.
2008 Ford Expedition 175,000 mi,
Chugging and misfire at about 50 MPH at slight acceleration changes. Not fixed - living with it.
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!
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.
2005 Ford Expedition 112,000 mi,
Spark plug issues. I have the same problem. I have bought several ford vehicles and this one has been my headache. First, transmission and now this. Well, Ford you have lost a customer. Recall this issue. Stand by your product. :(
A special tool had to be used to remove the broken spark plugs from my engine.
1997 Ford Expedition 107,211 mi,
I have a broke spark plug & it caused my pipe to burst open & my car keep shutting off when I stop at a stop sign & red lights & cut off when I get off the gas & put it in another gear I have to turn it bk on & it drives until I get to a light
2007 Ford Expedition 90,000 mi,
Buy extractor tool if diy before start.
2007 Ford Expedition 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.
2006 Ford Expedition - 4.6L V8 128,000 mi,
spark plug broke off
I role one of the spark plugs inside the head before anyone told me what to do . So now I have to find someone with that special tool to get it out
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