SPARK PLUG REMOVAL INSTRUCTIONS—4.6L TSB 08-7-6 3V/5.4L 3V .

SPARK PLUG REMOVAL INSTRUCTIONS—4.6L3V/5.4L 3V/6.8L 3VFORD:2005-2008 Mustang2004-2008 F-1502005-2008 Expedition, F-Super Duty2006-2008 Explorer,F-53 Motorhome Chassis2007-2008 Explorer Sport TracThis article supersedes TSB 08-1-9 to updateVehicle Applications, Service Procedure and PartList.ISSUESome 2004-2008 F-150, 2006-2008 Mark LT,2005-2008 F-Super Duty, Expedition, and Navigator,with 5.4L 3-V engine; 2005-2008 Mustang,2006-2008 Explorer, Mountaineer, and 2007-2008Explorer Sport Trac with 4.6L 3-V engine;2005-2008 F-Super Duty, 2006-2008 and F-StrippedChassis, with 6.8L 3-V engine may experiencedifficulty with spark plug removal. This may causedamage to the spark plug and leave part of thespark plug in the cylinder head. Affected enginebuild dates are as follows: 5.4L 3-V and 6.8L 3-Vbefore 10/9/07, 4.6L 3-V before 11/30/07.ACTIONRefer to the following Service Procedure fortechniques to remove the spark plugs and extractbroken spark plugs.SERVICE PROCEDUREThe engine build date can be read on the left handcam cover information sticker.To remove spark plugs without damage, it isnecessary to adhere exactly to this procedurebefore removal is attempted.TSB 08-7-6LINCOLN:2005-2008 Navigator2006-2008 Mark LTMERCURY:2006-2008 MountaineerCAUTIONDO NOT REMOVE PLUGS WHEN THE ENGINEIS WARM OR HOT. THE ENGINE MUST BE ATROOM TEMPERATURE WHEN PERFORMINGSPARK PLUG SERVICE. REMOVING THE SPARKPLUGS FROM A WARM/HOT ENGINEINCREASES THE CHANCE THE THREADSCOULD BE DAMAGED.Spark Plug Removal Procedure1.Remove the coil-on-plug assemblies andthoroughly blow out the spark plug wells andsurrounding valve cover area with compressedair.2.Back out the spark plugs no more than 1/8 to1/4 of a turn. Using Motorcraft CarburetorTune-Up Cleaner, fill the spark plug well justabove where the jamb nut hex sits (1/2 - 3/4teaspoon). A minimum period of 15 minutes ofsoak time is required. The cleaner will wickdown to the ground electrode shield and softenthe carbon deposits in this time. DO NOTWORK the spark plug back and forth at thispoint.NOTECOMPLETELY REVIEW THE PRODUCT LABELFOR THE MOTORCRAFT CARBURETORTUNE-UP CLEANER PRODUCT - USE AT ROOMTEMPERATURE AND SHAKE WELL.CAUTIONEXCESSIVE MOTORCRAFT CARBURETORTUNE-UP CLEANER, OR REPEATING THEPROCESS SEVERAL TIMES WITH TOO MUCHCLEANER FLUID, COULD INTRODUCE ENOUGHLIQUID VOLUME TO HYDRO-LOCK THE ENGINE.NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to dothe job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in propervehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact aFord, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentationdetermine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information isavailable through Ford Motor Company’s on-line technical resources.Copyright 2008 Ford Motor Company Online Publication Date April 1, 2008PAGE 1

TSB 08-7-6 (Continued)CAUTIONDO NOT USE AIR OR POWER TOOLS FORSPARK PLUG REMOVAL. SPARK PLUGS MUSTONLY BE REMOVED WITH HAND TOOLS.3.Tighten, and then loosen the spark plug,working the plug back and forth. Somescreeching and high effort may be noticed. Theexpected removal torque is about 33 lb-ft (45N m). Repeat the back and forth turning asneeded until turning effort is reduced, andremove the spark plugs.NOTENEW PLUGS SHOULD BE INSTALLED USING AFILM COATING OF MOTORCRAFT HIGHTEMPERATURE NICKEL ANTI-SEIZE LUBRICANTON THE GROUND ELECTRODE SHIELD. DO NOTCOAT THE ELECTRODE STRAP. (Figure 1)Figure 1 - Article 08-7-6Separated/Broken Spark Plug RemovalIf the spark plug separates after following the SparkPlug Removal Procedure, it will fail in one of threemodes. Refer to the appropriate removal procedureas required.Figure 2 - Article 08-7-6b. Mode 2: The entire porcelain insulator andground electrode shield remains in thecylinder head. (Figure 3)Figure 3 - Article 08-7-6c. Mode 3: The upper section of porcelainbroke off with remaining porcelain left insidethe ground shield. (Figure 4)a. Mode 1: The ground electrode shield is leftbehind as an empty shell. (Figure 2)Figure 4 - Article 08-7-6Flowchart of procedure. (Figure 5)PAGE 2

Figure 5 - Article 08-7-6PAGE 3

Mode 1 Procedure:2.Use the installation rod (J) provided withservice tool 303-1203 update to install themodified vacuum cap. Push the cap into theground shield down to the electrode strap. Thiswill plug and protect the combustion chamberfrom contamination. (Figure 7)3.Thread-tap the ground electrode shield using a9.0 x 1.0 mm plug tap (tap profile is about 3-4reduced diameter threads on the tip end).Use Rotunda special service tool 303-1203 toremove an empty ground electrode shield from thecylinder head. (Figure 6)a. Coat the end of the tap with generalpurpose grease. (Figure 8)Figure 6 - Article 08-7-6NOTETHIS TOOL IS ONLY DESIGNED TO WORK WITHAN EMPTY GROUND ELECTRODE SHIELD. IFPORCELAIN REMAINS, PROCEED TO MODE 2OR 3 REMOVAL.1.Modify vacuum cap to a 3/8″ (10 mm) lengthfor each ground electrode shield that needs tobe removed. (Figure 7)Figure 8 - Article 08-7-6b. Turn the tap about 3 to 4 turns into theground electrode shield. Back the tap upfrequently to break chips and avoid cutmaterial from coiling-up in the spark plugwell. A tap socket adaptor (K) is providedwith service tool 303-1203 update toconnect the tap to a 3/8″ socket drive.CAUTIONDO NOT ATTEMPT TO REMOVE THE GROUNDELECTRODE SHIELD WITH THE TAP ANDWRENCH. THE TAP MAY BREAK IF THIS ISATTEMPTED.4.Figure 7 - Article 08-7-6PAGE 4Thread Rotunda special service tool 303-1203into the ground electrode shield. (Figure 9)

3.Refer to Mode 1 Procedure to remove theremaining ground electrode shield from thecylinder head.Mode 3 Procedure:CAUTIONDO NOT DRIVE PORCELAIN DOWN INTO THEGROUND SHIELD WITH A PUNCH ASFRAGMENTS MAY ENTER THE COMBUSTIONCHAMBER.Use Rotunda special service tool kit 303-1398 toremove porcelain broken inside the groundelectrode shield. (FIGURE 10)Figure 9 - Article 08-7-6a. Install the stepped end of the tool pilotbushing into the spark plug well ensuring itbottoms out.b. Screw the center shank into the groundelectrode shield. Do not over tighten theshank, to prevent thread stripping.c. Install the nylon washer and jack nut untilfinger tight.d. Turn the jack nut until the ground electrodeis freed from the cavity and withdraw thetool assembly.NOTENEW PLUGS SHOULD BE INSTALLED USING AFILM COATING OF MOTORCRAFT HIGHTEMPERATURE NICKEL ANTI-SEIZE LUBRICANTON THE GROUND ELECTRODE SHIELD. DO NOTCOAT THE ELECTRODE STRAP.Mode 2 Procedure:1.Add an additional 1/2 teaspoon Motorcraft Carburetor Tune-Up Cleaner fluid into sparkplug well and allow 15 minutes of soak time.2.Using long-reach nose pliers grasp and removethe porcelain with an up and down motiontaking care not to fracture the porcelain.Figure 10 - Article 08-7-6Porcelain Removal - PreparationCAUTIONTHE ENGINE AND THE BONDING ADHESIVEMUST BE ROOM TEMPERATURE OF 70 F (21 C) OR HIGHER FOR PROPER CURE AND BONDSTRENGTH. VERIFY EXPIRATION DATE OFADHESIVE.CAUTIONDO NOT REUSE PINS. THIS ENSURES THECORRECT SURFACE CHARACTERISTICS FORBONDING.PAGE 5

1.Remove any remaining electrode material frombroken porcelain with long nose reach pliers.2.Spray Motorcraft Metal Brake Parts Cleanerinto the porcelain hole for 2-4 seconds usingthe straw nozzle supplied with the brakecleaner can.3.Insert a pin (A) into the collet (B). Screw thecollet onto the threaded rod (C). Install theassembled collet, pin, and threaded rod into thesteel tool pilot (F). (Figures 11 and 12)Figure 11 - Article 08-7-6Figure 12 - Article 08-7-64.Retract the collet and pin into the steel toolpilot, protecting the pin. (Figures 13 and 14)PAGE 6

Figure 13 - Article 08-7-6NOTEPIN TIP DAMAGE OR BENT PINS WILL PREVENTINSERTION INTO THE PORCELAIN.5.Insert the completed assembly into the sparkplug well and fully engage the pin into theporcelain. (Figure 15)Figure 14 - Article 08-7-6PAGE 7

Figure 15 - Article 08-7-66.Spray Motorcraft Metal Brake Parts Cleaner2-4 seconds between the spark plug well andsteel tool pilot. The steel tool pilot must belifted up approximately 1/2″ to allow brakecleaner to flood the porcelain and pin.7.Scrub the porcelain inside diameter by movingthe threaded rod up and down vigorously. Takecare making sure the pin does not disengagethe porcelain. (Figure 16).Figure 16 - Article 08-7-68.Repeat Steps 6 and 7.9.Remove the tool assembly. Again flood theporcelain with Motorcraft Metal Brake PartsCleaner for 2-4 seconds, then blow out theentire spark plug well and porcelain with drycompressed air.PAGE 8NOTECLEAN AND DRY COMPONENTS ARE KEY TOBONDING THE PIN TO THE PORCELAIN.10. Repeat Steps 1-9 to prepare remainingporcelain fragments as needed.

11. Disassemble the collet and pin from thethreaded rod. Dry the tools thoroughly with drycompressed air.Porcelain Removal - Bonding ProcessCAUTIONUSE CARE TO PREVENT BONDING AGENTFROM CONTACTING THREADS IN CYLINDERHEAD.NOTEWORKING TIME LIMIT OF LOCTITE 638 RETAINING COMPOUND IS 5 MINUTES.1.Apply two 3/4″ (19 mm) long stripes of Loctite 638 to opposite sides of a clean and dryapplicator (H). Excessive amounts of Loctite 638 are being used if it drips off theapplicator. (Figure 17)Figure 17 - Article 08-7-62.Insert applicator into the porcelain and moveapplicator up and down 1/2″ (13 mm) whileturning to spread the Loctite 638 on theinside of the porcelain. (Figure 18).8.Insert the completed assembly into spark plugwell and fully engage the pin into the porcelainwith a twisting motion to spread the bondingagent.9.Add additional Loctite 638 , repeating Steps6-8.Figure 18 - Article 08-7-63.Add additional Loctite 638 , repeating Steps1 and 2.4.Clean the applicator with Motorcraft MetalBrake Parts Cleaner before the bonding agentstarts to cure.5.Reassemble a dry and clean collet and pinassembly.6.Apply two 3/4″ (19 mm) long stripes of Loctite 638 to the pin. Excessive amounts ofLoctite 638 are being used if it drips off thepin.7.Retract the collet and pin into the steel toolpilot to protect the Loctite 638 coated pin.10. Leave the pin fully inserted in the porcelainwhile the adhesive cures. Replace the steel toolpilot with the aluminum alignment sleeve (G),Figure 9, to support the threaded rod while theadhesive cures if additional porcelain fragmentsare present in other cylinders. (Figure 19).PAGE 9