Here’s the low down......I’ve got a 2006 F-250 with the 5.4 v-8 3valve engine. I bought it a few years ago with around 40,000 on it and just turned 110,000. Last spring I developed the dreaded but common passenger side exhaust manifold leak. This is a very common problem on these engines and I wasn’t real concerned especially since it wasn’t terrible. The remedy is new manifold, gaskets and studs which are a PITA to get at. So I let it go for a while and was thinking of having it done at a shop. Problem #2...... right after start up initial acceleration it would stutter and then smooth out. If I tried to step on it while cruising it would misfire like crazy. While in OD going under light load would make it misfire. Well computer tells me I’ve got misfires on two different cylinders. Remedy to the situation... plug and coil change! Generally not a big deal but these engines have a coil for each cylinder that are really stuffed in. That’s not the worst problem! The plugs have an extended tip to reach the combustion chamber and the tips are notorious for breaking off in the head!!!! So I dropped $500 on new plugs, coils and the special extractor tool just in case. This is where the fun begins!!!!
Last Friday I started nice, slow and easy front plug on passenger side. Gentle, gentle snap crackle pop!! Twisted her right off!!!! Son of a ! No big deal I’ve got the super tool right? Set the tool to push the porcelain down to be able to draw out the little tip that’s broke. Hmmm .... strange.... the threaded puller just spins?! ohhh that’s because the driver tool pushed the entire plug tip into the cylinder!!! So now what? After a few moments of nausea, lots of choice words and thoughts of going to get the rifle to put her down I pulled it together and began prep for head removal!
The rumor is, if Ford does the plugs on a 5.4L, they want it for three days. Time needed to soak in penetrating oil so maybe the plugs will come out without twisting off. I feel for ya.
I soaked, and tried on a hot engine like they recommend. It’s a terrible design! I thought about taking it somewhere to have it done but glad I didn’t.
Last Saturday morning I tore into it!!! Intake, all front accessories and the radiator for more room. Valve cover one off
Sunday morning started in on a passenger side plug.... snap crackle pop twisted right off! Well might as well pull this head too and fix the exhaust while I’m at it! Got the other valve cover and timing cover off as well. Then realized I needed a special tool to take some of the rockers out in order to remove the timing set. Called it quits and ordered up the tool, a couple other timing tools and all the parts I figured I’d need. Fast forward to Wednesday after work.... Stripped the timing set and pulled the passenger head.
Thursday night... dressed up the head and replaced the exhaust manifold. It had two holes in the front cylinder and the studs were loose with a blown gasket on the rear cylinder. As for the plugs I broke three out of four on this head. Ended up using a brass punch and 24oz hammer to drive out the plug tips. The carbon build up acted like loctite! I couldn’t believe how hard I had to whack them! You can see the port where the plug sticks into the combustion chamber in between the valves.
Saturday morning... a bunch of cleaning and prepping to set the head. Put it on buttoned up as much as possible then switched sides. A view out of the door sitting inside the engine bay of the truck.
Here’s the one I started on and pushed in with the tool! The others, broke all 4 on drivers side! Put her back on lots of technical torque settings! Even a special custom tool
Saturday night..... did some more cleaning, got the timing set in, some new parts, seals and buttoned up the timing cover
Sunday.... got a late start went to breakfast and did some other stuff like pushing around the 8-10” of snow. Anyhow starting to take shape!!! Couple hours in the afternoon and that’s a wrap!!! Now the moment of truth!!! Cranked her with the crank sensor unplugged to prime some oil then plugged it back in. Rolled over fired and died, rolled over fired and died, rolled over fired and died!!! Got to be a sensor problem I figured and there was only one I didn’t mess with, the MAF so I unplugged it! Rolled over fired and ran!!!!! Plugged it back in instant stall. Luckily I’m off work today so I grabbed a new one and Houston we have ignition!!!!
All in all just under 30 hours maybe from what I read Ford calls for 26-28 so didn’t do too bad. I’ve probably got $1300 invested which is better than the $5-6000 I’ve heard of! Hopefully I’ll get a few more miles out of her! The plan is to hang a plow on it next year and make it my snow pushin’ wood wagon. I went with the champion one piece design plugs that should never break off and here’s the carnage. The only whole plug on the right. ironpony bets on left over parts you commented on the other day, didn’t figure I needed any of this stuff I
I bought the one piece extension plug socket as well figured it would be a nice tool to have. It worked great for its intended purpose.
Here’s a video of a Ford tech doing the same job in time lapse. Pretty cool!!! I did it without removing the coolers, a/c and core support in my not so nice Unheated garage with much less tools. This guy is good though!
I worked as a mechanic for 15 years. The first thing I did on a job like this was to deflate the front tires. It lowers the front end a few inches to make the engine compartment access a bit easier. The increased rake of the vehicle seems to improve access too.
