NHTSA Complaint #10637759 — 2005 FORD F-150

THE 5.4 LITER ENGINES HAVE A DESIGN PROBLEM THAT'S COSTING OWNERS A LOT OF MONEY JUST TO REPLACE THE SPARK PLUGS. THE PLUGS ARE TWISTING OFF OR BREAKING BECAUSE THE BLOCK DESIGN ALLOWS THE PLUG TO EXTEND INTO A HOLE THAT ALLOWS CARBON BUILDUP AROUND THE TIP OF THE PLUG. WHEN YOU TRY TO REMOVE THE SPARK PLUG THE BOTTOM OF THE PLUG IS SEALED TIGHT TO THE HEAD THEREFORE ALLOWING THE TOP OF THE PLUG TO TWIST AND NOT THE BOTTOM. THIS IS HAPPENING TO A LOT OF TRUCK OWNERS AND SOME DEALERS WON'T EVEN ATTEMPT TO REPLACE THE PLUGS. IF ONE BREAKS, IT COULD COST UP TO $2000 FOR THE REPAIRS. I HAVE 4 OF THEM BROKE OFF. I HAVE ORDERED THE EXTRACTOR KIT BUT THE BACK TWO CYLINDERS ARE GOING TO BE HARD TO REPAIR. I LIKE MY FORD TRUCK BUT SINCE THE EARLIER MODEL FORDS WERE BLOWING PLUGS OUT OF THE BLOCKS AND NOW WE CAN'T GET THEM OUT WITHOUT AN EXTRACTOR, TO ME THIS IS NOT GOOD ENGINEERING. I WOULD LIKE TO KNOW WHAT FORD IS DOING ABOUT THIS EXTREME COST TO ITS CUSTOMERS. THANK YOU, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR