NHTSA Complaint #10340208 — 2006 FORD F-150

DURING ROUTINE MAINTENANCE SPARK PLUG CHANGE SIX OF THE OEM INSTALLED SPARKPLUGS BROKE OFF IN THE CYLINDER HEAD OF THE ENGINE. FORD DEALER ADMITS TO HAVING PROBLEMS WITH THIS DESIGN ENGINE AND STATES THIS OCCURS OFTEN. FORD DEALER STATED THAT FORD ADMITS AN ISSUE WITH THIS DESIGN SPARKPLUG AND HAS A TSB DETAILING THE PROCEDURE FOR BROKEN PLUG REMOVAL BUT HAS ISSUED NO FORMAL RECALL. DEALER ADVISED THAT FORD ALSO HAS A "SPECIAL TOOL" DESIGNED FOR THIS 5.4 3 VALVE SERIES MOTOR THAT IS ENGINE SPECIFIC TO REMOVE THE BROKEN PIECE OF THE SPARKPLUG BECAUSE THIS HAPPENS SO OFTEN. ALL BUT ONE OF THE BROKEN PLUGS WAS ABLE TO BE REMOVED USING A SPECIALTY TOOL PURCHASED AT AN AUTOMOTIVE PARTS STORE. FORD DEALER WAS UNABLE TO GET THE LAST BROKEN PLUG EXTRACTED FROM CYLINDER HEAD WITH THEIR "SPECIAL TOOL". ENGINE NEEDED TO BE DISSEMBLED AND CYLINDER HEAD REMOVED SO THAT THE BROKEN PIECE COULD BE EXTRACTED. THIS REPAIR COST $1708.00 TO COMPLETE. ALONG WITH $85.00 DIAGNOSTIC FEE TO TELL ME THEY COULD NOT GET THE BROKEN PIECE OUT. THE REPAIR TOOK TWO WEEKS TO HAVE COMPLETED. I FEEL THAT FORD SHOULD ISSUE A RECALL FOR THIS ISSUE AND THEY SHOULD REIMBURSE ME FOR MY COSTS DUE TO THEIR FAULTY DESIGN FLAW. *TR