Spark Plug Removal Techniques On Ford Modular Engines
GM Active Fuel Management System Service
Understanding Stop/Start Charging and Starting Systems
The Importance of Changing Cabin Air Filters for the Winter
Spark Plug Removal Techniques On Ford Modular Engines
GM Active Fuel Management System Service
Understanding Stop/Start Charging and Starting Systems
The Importance of Changing Cabin Air Filters for the Winter
Sponsored By NGK Spark Plugs
Transmission Fluid Technology: Your Guide to Understanding New Grades and Specifications
As automatic transmission technology has evolved, so have the fluids inside. With more than 20 current OE transmission fluid specifications, it can be confusing to choose the correct fluid for the transmission and customer.
In this 60-minute webinar, our presenters will discuss how to select the correct transmission fluid for today’s diverse population of automatic transmissions. The experts will also cover how to optimize your shop’s inventory to cover the broadest range of vehicles.
Speakers Mark Thorsen, Transtar Account Manager, Lubrication Technologies Mike Quigley, Director of Product Development, Lubrication Technologies Andrew Markel, Director of Content, ShopOwner
Underhood Service targets repair shops that derive 50 percent or more of their revenue from the service and repair of under-the-hood systems. The expanding amount of knowledge and capital needed to keep up with technological advances has led these shop owners to concentrate on underhood systems, while also offering preventive maintenance services on most major vehicle systems. By subscribing, you’ll receive the ShopOwner digital edition magazine (12 times/year) featuring articles from Underhood Service and the Underhood Service eNewsletter (twice weekly). Access to digital editions, contests, news, and more are ready for you today!
Underhood Service targets repair shops that derive 50 percent or more of their revenue from the service and repair of under-the-hood systems. The expanding amount of knowledge and capital needed to keep up with technological advances has led these shop owners to concentrate on underhood systems, while also offering preventive maintenance services on most major vehicle systems. By subscribing, you’ll receive the ShopOwner digital edition magazine (12 times/year) featuring articles from Underhood Service and the Underhood Service eNewsletter (twice weekly). Access to digital editions, contests, news, and more are ready for you today!
ByUnderhood Service Staff Writers on Feb 25, 2022
High underhood temps, increased power demands and vibration can damage alternators or starters. Sponsored by ACDelco.
Don’t settle for “almost” - it matters where the engine is manufactured or remanufactured. Sponsored by ACDelco.
Brake pads are thoroughly developed to produce the best result. This video is sponsored by ZF Aftermarket.
Click here to view past issues.
Get the latest news, insights, and more delivered directly to you inbox.
Ford’s Modular engine has been known to give techs a hard time during a spark plug replacement.
The problem with removing spark plugs from various Ford Modular engines lies in excessive carbon buildup on the plugs, especially on engines that have gone beyond an OEM-recommended replacement interval. This can cause a plug to break in the chamber during its removal, creating stress on the tech and additional labor time to remove the damaged component.
Ford’s Modular engine, used in various Ford, Lincoln and Mercury products during the mid- to late-2000s, has been known to give techs a hard time during a spark plug replacement.
What is the cause? It comes down to the design of the spark plug. These plugs have a small tip with a strap for an electrode. The smaller tips allow for bigger valves and optimized intake and exhaust ports. Instead of having the threads near the end of the spark plug, the threads are higher on the body. The tip without threads is pushed into a hole.
The issue with these plugs is not the threads, it is the tip. The tip becomes seized in the hole due to carbon deposits. Before the tip comes out, the spark plug breaks below the threads and you are stuck holding onto a tipless spark plug.
There are several non-authorized methods for removing these spark plugs. Some recommend removing the plugs when they are hot. Other procedures recommend a 3/8” impact. Most recommend using a solvent or penetrant in the well of the plug, including the recommended Ford procedure.
But the one thing all of these methods recommend is having a tool to remove the tip of the plug from the head before you try anything. It is not a question of if but when a plug will break.
Some techs who have come across the broken plug problem recommend performing an engine flush the day prior to changing out the spark plugs and letting the vehicle sit overnight as a way to loosen up the carbon deposits, allowing for less of a chance for a plug to break. This might not be an option, as many customers expect a spark plug replacement job to be completed the same day.
Ford recognized the plug removal problem and issued a tech bulletin — TSB 08-7-6 — to address the problems associated with plug removal on various Ford vehicles. This article supersedes TSB 08-1-9.
According to Ford, some F-150s, Mark LTs, F-Super Duties, Expeditions and Navigators with the 5.4L 3V engine; Mustangs, Explorers, Mountaineers and Explorer Sport Tracs with the 4.6L 3V engine and F-Super Duties with the 6.8L 3V engine may create difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head.
Affected engine build dates are as follows: 5.4L 3V and 6.8L 3V before Oct. 9, 2007, 4.6L 3V before Nov. 30, 2007. The engine build date can be read on the left-hand cam cover information sticker.
To remove the spark plugs on these engines without damage, it is necessary to adhere exactly to this procedure before removal is attempted.
Caution: Do not remove plugs when the engine is warm or hot. The engine must be at room temperature when performing spark plug service. Removing the spark plugs from a warm/hot engine increases the chance the threads could be damaged.
Ford says do not use power tools for the plug removal — spark plugs must be only be removed with hand tools.
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required.
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head.
Note: This tool is only designed to work with an empty ground electrode shield. If porcelain remains, proceed to Mode 2 or 3 removal.
Caution: Do not drive porcelain down into the ground shield with a punch as fragments may enter the combustion chamber.
Note: Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield.
Caution: The engine and the bonding adhesive must be room temperature of 70° F (21° C) or higher for proper cure and bond strength. Verify the expiration date of the adhesive.
Caution: Do not reuse pins from the tool kit. This ensures the correct surface characteristics for bonding.
Engine: Understanding Electronic Throttle Controls
Engine: Tool Up For Belts
Engine: Belt-In-Oil Timing Systems
Engine: Duramax 6.6L Turbocharger Replacement