Not sure if this it the right place. I'm attempting to change out my plugs. A 5/8" plug socket didn't fit. Found a 15mm deep socket to remove some type of insert. After removing the insert, the plug doesn't come out. I notice there's a liner of some type in the outer hole for the spark plug. How do you remove the liner to be able to put a plug socket on the plug? 2004 F150 FX4 w/ the 5.4L engine. See attached photos.

Not for sure but I think u just pulled the tread out and left the plug part in the hole. These trucks suck on the plugs. Ford has a tsb on the issue and u have to put penertaing lube down the hole and turn it a 1/4 of a turn and then repeat the process. Most of the time u have to drill it out. It is a new plug size 9/16 I believe. I no they suck. Why did u change them, they r 100,000 mile plugs.

Not much help here. Not familiar with the 3V motors

Oooh....lousy thing to have happen right there. There are issues with those plugs...even the Ford techs wind up pulling the heads to get them out.

Don't know if this info will help you know but things to consider for the future:

1. Engine has to be warm, not hot, before attempting this.
2. Blow out spark plug wells with compressed air.
3. Spray liberal amount of penetrating oil into the plug well (Aero Kroil is best here) until you have enough to cover the hex head on the jam nut.
4. Loosen 1/8 to 1/4 turn at a time...could need some considerable effort. Work a back and forth to avoid stripping theads and breaking jam nut.
5. Pray it all comes out in one piece.

Sadly yours failed in one of two common failure modes. You either just get the jam nut (your case) or the jam nut + ceramic center piece. What you'll need to do now is take it to a dealership. There is a special tool set to remove the ground shield but seems only dealerships have it.

Oooh....lousy thing to have happen right there. There are issues with those plugs...even the Ford techs wind up pulling the heads to get them out.

Don't know if this info will help you know but things to consider for the future:

1. Engine has to be warm, not hot, before attempting this.
2. Blow out spark plug wells with compressed air.
3. Spray liberal amount of penetrating oil into the plug well (Aero Kroil is best here) until you have enough to cover the hex head on the jam nut.
4. Loosen 1/8 to 1/4 turn at a time...could need some considerable effort. Work a back and forth to avoid stripping theads and breaking jam nut.
5. Pray it all comes out in one piece.

Sadly yours failed in one of two common failure modes. You either just get the jam nut (your case) or the jam nut + ceramic center piece. What you'll need to do now is take it to a dealership. There is a special tool set to remove the ground shield but seems only dealerships have it.

Good Advice, we have used this technique every time we do plugs on a 3v motor. We also have a set of heads for back up! :eek2: Matco and SnapOn have that tool available also ;)

Yeah....I think I prefer my plugs blowing out of the cylinder head rather than getting a piece of a plug stuck in one...:D

Yeah....I think I prefer my plugs blowing out of the cylinder head rather than getting a piece of a plug stuck in one...:D

thats a BIG 10-4 :jest:

Thanks for the info everyone. After finding more horror stories on the F150 forum, I put everything back together, returned the coil packs, and spark plugs to the store. I then found the necessary tap to correct my stripped 02 sensor. Repair that issue and changed the oil. Told myself the truck is going to dealership to have this done since they have the tools to fix it if one or more breaks off in the head(s). Ford MoCo took the fun out of working on this motor.

Fun? What could possibly be more fun than drilling into your own cylinder head while it is still in the engine bay? Oh....putting in a TimeCert for a popped #2 plug with just basic handtools in the middle of your college campus' parking lot...:D


Ford wants it fun.

My friends moms expedition blew the plug out along with the coil pack. Fucking shattered that thing.

Been there done that. It sucked hard core. Ended up tapping the plug and pulling it out.

i had that problem with two of my plugs. man what a pita. i was soaking it in lube and tried everything. i ended up welding an easy out to the end of a big screwdriver and got them out. blew and cleaned out the cylinders and stuck in new plugs. oh yay. i even went as far as to polish the inserts on the plugs a little so that it wont be so hard next time. good luck.

im a tech at a ford dealership and we've had lots of problems but i haven't seen anything like your pics you posted mainly the shanks break off in the heads we end up pullin the heads, we had a problem with ford's issued tool to fix this concern but the damn thing busted off in the head to. "QUALITY" ford need to get the shit straight plus the electronic throttle plate has way to much delay time.

ford has had a few issues with plugs blowing out of the heads.... and a ford tech i am friends with... says that in alot of cases it requires cyl head replacement :(

those pics posted look exactly like what happened to me on one of my plugs. the best of luck to ya. oh yay if you are going to try to do it yourself then dont forget to put some grease on whatever you are using to keep the shavings and trach to a minimum.