Subject: 2004 F-150 w/3 valve 5.4 Triton Engine RE: Spark Plugs
Date: 12/8/2005

Purchased vehicle December 03, no problems other than a recall for a
rubber pad in cargo bed. Best truck I've ever ridden in or owned.
Dealer is and has been perfect in every way,100% of service performed
by Ford dealers even oil changes. In for 60K mile service. Service
writer calls, says #4 and 8 spark plugs are stuck in the head! tech
has broken them off. Carbon has built up around the electrode extension
freezing them in the head. Go back to dealer ,look at the removed plugs
and the broken ones. Plugs broke off at end of the threads. Strange
designed plugs, they are similar to English sports car plugs from the
60's or old oil furnace electrodes.  Soaked the broken plugs over the
weekend so they might come out Monday AM by cranking the engine ? This
plan did not work and heads had to come off.  Have an automotive back
ground and understand what is going on BUT what  were the Ford engineers
thinking when they designed those heads? Internet search shows 1000's of
complaints concerning spark plug blow outs in earlier Fords but nothing
similar to this problem. How many of these engines are out there?  When
they reach 60K and need a tune up will Ford pay for both heads to be
removed?They are paying for this but what other problems may result from
removing the heads beyond the 12K miles or 12 month warrantee.. Things
will get interesting today..............DCR