Hello, I am new to this sight. I was referred by a really helpful employee at O'Reilly Auto Parts in Temecula, CA. Anyways I have a 2004 F150 and I am doing a tune up on it. I recently had to replace the motor and I replaced it with a used one with 3000 miles. Good deal right? Wrong the mechanic apparently never changed the plugs and they were rusty. 2 of them broke off inside (the spark half the metal piece). Besides taking the head apart is there anything I can do to get them out? I have already done 6 of them. I can't turn around now and take it to a mechanic. Can anyone help me? Please. And Ford, please listen, why can't we at least change our spark plugs? A man (or woman) should at least be able to do that.

 

There are a few aftermarket tools available to remedy this problem without removing the heads. You might check with your auto parts supply store. Its a common problem. Two suggestions I might make are, soak the living daylites out of the plugs with penetrating oil and let them soak overnight. The carbon builds up on the extending thread portion and when you try to remove them the carbon just jams up everything. When replacing them , Champion makes a one piece plug that doesn't break off in the middle. Possibly Ford has changed that plug design ,not sure.

 

Ford has also changed the design. Lisle makes a kit to remove the broken plugs too.. We have found that using a 3/8 inch impact to remove them works really well. We have used it on 3 vehicles and have not broken a plug. Using hand tools we usually break 2 to 4 each time. Lisle Ford Broken Spark Plug Remover LIS 65600 (Alt 303-1203 303-1398) | Hard to Find Automotive Specialty Tools

 

All 8 plugs broke off in my 2004 F150. The lisle tool part #65600 built specifically for Triton 3 valve motors. it is $100 and worth every penny. it pulled out all eight pieces. Good Luck