spark plug break off, internal

20

Asked by Gary Jan 12, 2018 at 10:47 AM about the 2004 Ford F-150 Lariat SuperCrew 4WD

Question type: Maintenance & Repair

i have an 04 f150 4x4. i was getting a rough idle and
coughing and backfire under acceleration. i took it to my
mechanic and we changed 02 sensors. codes read lean and
cylinders 4 and 8 misfire. he said he found a leak in intake
so he took it off and replaced intake gasket. he said he
found a spot where it was leaking. the truck ran great for a
few miles, 5 to15, then would start chugging and puking and
backfiring again. lost power every time. i could pull over and
let idle for 30 seconds and run good again for a few miles.
he did a compression test and when he pulled out sparkplug
on #8 the bottom of spark plug was missing. can't find it.
the compression on #8 was 20#. we suspect it broke off
and went the the exhaust valve. i tried to drive it home and it
had rougher idle then ever and would die at stoplights. i
would have to jump start it to get it going. seemed like
something was in a bind. (hard to turn over). then i couldn't
get igt to turn over at all.  made it halfway home and had to
tow it the rest of the way. any thoughts? is motor blown?
should spark plug manufacturer be responsible for repairs?
HELP

4 Answers

101,615

How many miles on motor? May be due for a head job. If it's very high on miles might be better going with a full rebuild or replacement motor. I don't think you're going to get very far trying to go after a spark plug manufacturer. You'd have to prove it wasn't overtorqued, something people constantly do. If the electrode became brittle from carbon buildup and heat, it may come off. Can your mechanic run a borescope into the cylinder to see what's going on?

There is a special tool for removing broken spark plugs on those 3V engines. https://www.amazon.com/Lisle-LIS65600-Broken-Remover-Engines/dp/B00267PZUK

1 people found this helpful.

If the plug was blown out you can also repair the hole in the head. Also use a one piece plug next time instead of the factory 2 piece plug.

1 people found this helpful.
20

122,000 miles he doesnt have a scope just a mirror so he can't see the valve. thanks for the answer on spark plug manufacturer. i can assume its time for a motor or head job then. i was really just wondering if anyone had heard of spark plug breaking off in side of cylinder. thanks

2 people found this helpful.

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