Spark plug replacement rear most plugs?

JOHND2865

MEMBER
2003 FORD EXPLORER
4.6L
V8
2WD
AUTOMATIC
217,000 MILES

Hello,

Thanks for this service. I am a pretty good DIY guy. I am replacing the spark plugs on my vehicle listed above Limited Edition. I have replaced the 6 front most plugs on both sides but the rears are making me crazy. I got one plug out, but can't seem to get the new plug to grab threads as I put it back in. As I look down the spark plug hole, I see it is at an angle, is there a trick in getting it to line up, some magical thing you guys do to get it replaced? The other issue is that the other rear (closest to the firewall on both BTW) I can't seem to get either of two spark plug sockets to grab onto the nut piece. I have ordered two new spark plug sockets are 12pt instead of 6 pt to see if I can get the socket to grab on. Any and I mean Any advice or thoughts you might have would be so very appreciated. Thanks for taking time to read this desperate note LOL Best Regards JD

6 Replies

KEN L

MASTER CERTIFIED MECHANIC
47,642 POSTS

Yep, that can be tough, what I would do is use a short piece of rubber vacuum line and attach it to the wire side of the spark plug this can help you rotate the plug and gain the angle needed, also when trying to tighten the spark plug the insulator inside the socket can be to tight which makes it difficult to install fully onto the plug, you might what to try removing the isolator for these spark plugs, just be careful when tightening the plug as not to crank it. Please let me know if this helps.

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Thursday, September 21st, 2023 AT 1:08 PM

JOHND2865

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Ken, Thanks for the tip. I found out that one cylinder had another issue which was easily fixed. So, 7 plugs are in with all new Coil on Plug electrics attached, I replaced 5 electronic clips that hold the leads to the Coil on Plugs, so they are now working perfectly. However, the last plug, closest to the firewall on the Driver's side has an issue I don't think is fixable. I have now tried 3 different spark plug sockets and none can grab hold. The reason I believe is that when that plug was put in 10 years ago, it was most likely cross threaded because part of the plug is canted so the spark plug socket can't get around the nut, no room on that side. I did put on a new coil on plug anyway, took it out for a drive and the car is working quite well. I guess I am going to have to live with it, new coil on plug, old plug unless my mechanic or any mechanic can find a way to grab onto the porcelain part of the plug spindle and get it lose enough to get it out. I wonder if that is a tool especially made for doing just that, anything like that in your bag of tricks? In any case, I forgot about the rubber tube trick I will keep that handy for future use. Thanks again. JD

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Friday, September 22nd, 2023 AT 7:29 AM

JOHND2865

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5 POSTS

Hi again, one thing that might work is a broken spark plug drill where the porcelain has broken off. I know that make special tools for taking out a broken spark plug, thing is my mechanic would have to break it off. Just thinking out loud. Thanks JD

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Friday, September 22nd, 2023 AT 8:36 AM

KEN L

MASTER CERTIFIED MECHANIC
47,642 POSTS

Yep, it does sound cross threaded, it happens, if you break the spark plug porcelain and then socket will fit. Then you will need to install a helicoil when the cylinder is on TDC and then use compressed air to blow any metal chips from the combustion chamber.

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Saturday, September 23rd, 2023 AT 11:55 AM

JOHND2865

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Ken,

The car is working very well. My plan for the immediate future is to leave it alone for now. The new coils on plug seem to be working perfectly and that old plug is not a bad plug, just old and it seems to be firing quite well. At some future date, I will have my mechanic deal with it. I bought an inexpensive borescope that is coming tomorrow, I will take a pic or two of it to show my mechanic and then we can work out how to deal with it and I will show him your recommendation. Thanks for all your great help. I will send something on the GoFund me page, send me the link if you can and have the rest of a great weekend. JD