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Tools Required J38491 Spark Plug Heat Shield Removal Tool 1. Turn OFF the ignition switch. 2. Remove the spark plug wires from the spark plugs. NOTE: ^ Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. ^ Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure NOTE: ^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. ^ Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gage to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed and correct as necessary. Spark Plug Gap: 0.060 in (1.52 mm) NOTE: ^ Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage.

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ISSUE Some 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 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience 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 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs 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. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 – 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT – USE AT ROOM TEMPERATURE AND SHAKE WELL.

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1. Disconnect the spark plug wire at each spark plug. ^ Twist the boots 1/2 turn before removing the boots. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. Install the spark plug wires at the distributor. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot.

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1998-2002 Continental FORD: 1998-2006 Town Car 1996-1999 Taurus SHO 2000-2006 LS 1998-2006 Crown Victoria, Mustang
1998-2006 Navigator 2000 Taurus 2002-2003 Blackwood 2002-2005 Thunderbird 2003-2005 Aviator 2003-2006 Focus
2004-2006 Taurus MERCURY: 2005-2006 Five Hundred, Freestyle 1998-2006 Grand Marquis 1997-2006 E-Series, Expedition, F-150
2000 Sable 1999-2006 F-Super Duty 2004-2005 Sable 2000-2005 Excursion, F-53 2005-2006 Montego 2001-2006 Escape 2002-2005 Mountaineer 2002-2005 Explorer 2005-2006 Mariner 2005-2006 Escape Hybrid 2006 Mariner Hybrid LINCOLN: 1997-1998 Mark VIII This article supersedes TSB 04-16-01 to update the vehicle applications and model years.
NOTE
FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING
EXPERIENCED. ISSUEnApproximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.
ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues).
Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem.

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Engine miss, spark knock, buck/jerk, surge and other driveability concerns may be caused by induction crossfire. This occurs because of improperly routed spark plug wires. ACTION: If spark plug replacement is performed, the correct firing order and spark plug wire routing is essential to prevent the possibility of induction crossfire between cylinders. Refer to the following procedures for inspection of the spark plug wire routing and firing order. Properly reroute the spark plug wires if required. FIRING ORDER ^ The firing order for 1987-1993 vehicles is 1-5-4-2-6-3-7-8. If # 7 and # 8, or # 2 and # 4 spark plug wires are routed next to each other at the separation bracket, an induction crossfire condition can occur. ^ The firing order for 1994 vehicles is 1-3-7-2-6-5-4-8. On these vehicles the # 1 and # 3, or # 5 and # 6 spark plug wires must be separated to eliminate the possibility of an induction crossfire. ^ To eliminate the possibility of the coil wire becoming disconnected, route the coil wire under the spark plug wires at the distributor cap. 1987-1993 VEHICLES