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#1 Spark Plug Broke I am in hot water now!

Mr.Mel

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2019 XLT with 84,000 Miles location Ohio. This truck is my working baby and I thought I would change the plugs and coils as I am proactive on Maintenance and like to have all Service slated for 100K miles done between 80 and 90K. I am a do it your self-kind of guy and had in fact changed my wife’s plugs and coils in her Sonata the week prior and that took all of 20 minutes for all 4 plugs and coils and slam bam done.

As a long time member of this group I had seen the mention of the Service Bulletin for water intrusion and had bought the engine cover at my expense ($75 back then) in the first 2-3 years I owned my Truck primarily for that reason. I mainly store this in my garage or under cover at the airport when I am traveling for work.

So I pulled #1 and the Plug cap was stained red at the bottom from rust and the bottom of the plug well caked up with rusty water. I blew out all of the crud and fished around and scraped crap loose with a coat hanger and kept blowing stuff out and actually got it pretty clean. I started dosing with Blaster and went on and replaced the other 3 plugs, 2 and 4 not bad 3 pretty tight but gave in, all of them squeaked and seemed to object to coming out. I was then ready for 1 and it was not budging so I let it sit overnight soaking. Next day still not budging so I put the coil back on and ran the motor and warmed things up to try again. Still did not budge so had some places to go and let it soak for about another 24 hours. Tried warming up again and still did not go, repeated again and I felt a small movement and a little noise so immediately stopped to try to turn it back slightly with the intention to rock it back and forth and let the juice soak in. Well, the slight back pressure broke the plug off, threads are in the hole and the porcelain clear to the tip and hex are in my hand.

I am so frustrated that something so simple has been turned into a full-on mess by doing a plug change I have done literally dozens of times. And I guess at this point I have it towed and Ford will compound their design fail by costing me for $$$ in a repair let alone a Rental Car. I do have the Ford extended Warranty but am looking forward to that being of no use.

Like many of you I love the truck and have been buying Ford’s since my first bronco in 1974, then 4 rangers, Tempo, 2 Escapes, Fusion etc. We will see how that loyalty stays with me now. I had great fun poking at my Wife for buying her Hyundai and look who is on the receiving end now, well not right now unti l cool down she knows betetr than that but I know she will call me out on my FORD! LOL.

Not sure what I will be running into but I will keep you all posted as a caution.

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RedlandRanger

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Wow - that really sucks - sorry to hear it. I will be interested to hear what the dealer says.
 

AzScorpion

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Sorry you had trouble doing what should've been an easy routine job. This is another reason I stopped working on my vehicles and just let the shop do it now. I use to really enjoy it but not anymore. It seems that most times when I try to do something that should be easy (and only take a few minutes) usually ends up taking me 3x's longer and my neighbors learn new swear words. :curse: Good luck with the dealer!
 

Friday yet?

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I was literally driving home from work today thinking, “At 60K I’m gonna change the plugs.” Now? Not a snowballs chance in hell!

Wish you the best with it OP. This really sucks. Just totally uncalled for.
 


DukeCanBuildit

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jflogerzi

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do not wish this upon my worst enemies let alone a normal person. Hopefully dealer can extract it and with minimal time but we all how some stealships operate. Good luck and just remember good karma and things always have a way of working themselves out.
 

ctechbob

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My guess is that it will need to be drilled down through with a bit that is ever-so-slightly smaller than the threads. Making what's left thin enough to break out.

Or just drill down through it and install a timesert. That wouldn't be the most terrible thing ever. Sucks, but it isn't a death sentence.
 

DukeCanBuildit

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Jason B

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Knowing Ford, plugs are not covered under any warranty, OEM or ESP.
I don't think they will put much effort into extracting it, so you are probably looking at a new head.
If they do manage, first thing to do is take it home, remove the plugs and add a little Never Seize to the threads.
 

ScarzRanger21(2.0)

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I feel for you… Nothing is worse than having what should be an easy project turn into a nightmare. Can’t say I’ve ever had a plug break off but I’ve had threads strip out when installing. With my last truck, I had to install a couple Helicoils over the years. Good luck man, hopefully the dealership (or you if you try it yourself) can handle it without it costing an arm and a leg. Let us know how it goes!
 

Muscleford

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Will / does the engine cover help prevent this issue?
 

AzScorpion

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Will / does the engine cover help prevent this issue?
It helps but it doesn't alleviate it. Knowing what we know now it's best to pull them out when new and add anti-seize to them.

Or you can do what Robert @NotBudule2 did and add this to it to deflect the water.

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airline tech

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I would try a #4 or #5 - Straight Fluke Easy Out - Which ever one of the (2) will grab the thread boss without expanding it - (Increasing friction) in the thread hole.
This is pretty much the (Only Option) now besides head replacement

You can find either:
Long - Straight Fluke (Extractors) + T-Handle
Or
Standard Length (Extractor) + Tap Socket + 3/8 Extension + 3/8 Ratchet

I would recommend the (Straight Fluke) over the spiral extractors for this - as you need to prevent expanding (Wedging) the remaining boss into the threads making it even more of a challenge.

Note:
I know what it takes to get it out, but would have to do some digging on the proper tool setup, with this being in a recessed well. - Which one would be the (Best Option - For Success)
I think that they make a special tool set for this as well.
I am confident that you can get it out - without head replacement, as long as you continue the baby steps and not be aggressive with it.
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