Are there any Issues with Replacing the Spark Plugs in my 2003 with the 5.4 Engine??

Hey all.

I’ve been told by a family member about spark plug problems in the motor I have. He said the plugs they used had a chance of breaking off while trying to remove them. He is very leery of replacing the plugs for me. I’m clumsy and now I’m afraid too that I’d break a plug off while I was trying to get it out.

So, are there any issues to worry about when replacing the factory plugs in my 2003 Eddie Bauer 5.4. Is there anything I should be aware of with this repair? If I’d break one off, I’d be in BIG TROUBLE cause I’d guess that’s a really expensive repair.

Any help or advice you all can give me would be really appreciated. Thank you all.

That is primarily the earlier 3v motors that started in 2005. The 2v had issues w plus being blown out of the head, equally bad day.

Theres quite a bit of video/diy out there for reference. Watch a couple and provided you use the proper tools it shouldn't be too difficult. Fordtechmakuloco has a rather extensive youtube channel with a large focus on the expedition.

I have a 2004 Exp Eddie Bauer with a 5.4 in it if you are doing this at home and not a shop y7ou are oaying be sure and rent the spark plug removal tool from your lockol partsd supply tomhave on hand just incase you twist one off

I had read some of those articles too so was super paranoid when I did the plugs on my '03 2 years ago. Decided I'd throw caution to the wind and give it a shot. Had zero problems.

I have done this a couple of times now and it not that big of a deal just take your time and have the correct sockets, nuckles, and extensions. The passenger side rear is the most challenging to get to. What I have found to be the easiest way for me to maneuver through is to take out the air intake system and remove the battery, I also took off the PCM (but don't remember if that was necessary, been a while)

Then take of the COPs and spray in some penetrating fluid into the spark plug holes (I let penetrating sit overnight (I took off COPs the night before sprayed fluid then started the job in the morning) In the morning I put the COPs back on the started truck to warm up a bit then started the job.

Sounds like a lot but was easy took about an hour and a half total. I reiterate go slow and best practices, while your at it get throttle body cleaner and MASS airflow cleaner and spray those parts and get air filter if needed, should be all good.

Sometimes the plug boot gets stuck on the plug, so only the coil comes free. If this happens you can slide a thin piece of baling wire down thru the center of the plug boot, and with a little fiddling, down along the side of the plug. Spray a little WD-40 down the recess created by the wire. This will lubricate and free the stuck plug boot, you can then withdraw the wire, and remove the plug boot with a needle nose pliers or forceps. This technique will remove the plug boots with no damage, works on other engines of similar design.

The hardest part , to me anyway, was just accessing the pluhs, especially the #4 nearest the firewall on passenger sie. I removed the fuel rail, too off the plastic crap over the intake, then used bungie cords to keep the heater hone and a/c hoses out of the way. Once you get the spark plug loose, if it doesn't come out with the socket I used 7mm fuel hose to push it down on top of the plug and then just pull it out. Oh year, of course you have to take the coils off each plug . I laid a narrow piece of plywood across the engine bay and rested my upper body on it while I fumbled with a the crap that is blocking access to the plugs. I'm not a violent man, but if the genius who designed this ever showed up in my neighborhood, well I won't say what will become of him

Most of the time, it's not an issue. Most of the time.
But, there have been enough problems that Ford is catching hell for their stunning lack of support.
Apparently (and I could easily have this exactly backwards) the 2V engines don't have enough threads, and they are soft and easily stripped. So, check out youtube videos for how to minimize the damage. There are special tools and TBs on the subject, research the crap out of it first.
the 3V heads are two piece and are quite likely to break, leaving one part in the head. this is a major $$$ repair job, and Ford absolutely does not stand behind their work, or their design. If they break it, you buy it. As before, there are tools, TBs, and videos. Research is your friend.
I got lucky, the previous owner replaced the plugs before I got mine. If I had to do it myself, I would find a professional who has suffered through breaking the plugs/threads, so they have the experience. Then I would discuss it with them before I risked a few thousand dollars on a damaged head.

You have a 2V motor- it’s easy. Hardest thing is access to the ones by the firewall.

they will break off...those that says 2v wont happen it will...i have 04 and took ford 2 days cuz they broke off in the engine...oem motorcraft plugs