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pretty bad
Typical Repair Cost:
Average Mileage:
84,341 miles
Total Complaints:
40 complaints

Most Common Solutions:

  1. not sure (12 reports)
  2. remove heads (11 reports)
  3. purchase special removal tool (9 reports)
  4. don't buy a ford (3 reports)
  5. replaced with new unbreakable plugs (3 reports)
  6. helio coil, new coil, new plug (1 reports)
2006 Ford F-150 engine problems

engine problem

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2006 Ford F-150 Owner Comments (Page 1 of 2)

problem #40

Aug 032015

F-150 Lariet 5.4L Flex Fuel

  • Automatic transmission
  • 132,000 miles


The dealer broke the spark plug off and has to pull the engine, just to replace the plugs due to poor design. Instead of Ford recalling and replacing them, we are stuck with almost $3000 for changing 8 spark plugs. Ford should help with the cost of this problem because a dealer can make a lot of money by saying they broke and will have to pull the engine. My last Ford.

- , Kiowa, OK, USA

problem #39

Aug 192015

F-150 XLT 5.4L

  • Automatic transmission
  • 77,550 miles

I had a tune up, A/C and O-2 sensor repair go from $1470 to just under $3400. There were 3 plugs that broke off in one of the heads. The procedure involves removing the entire cab to get to the plugs to be extracted. This is a problem that Ford knew about but will not own up to it. I have been buying Ford F150 trucks since 1987 and have had minimal problems up until now. You would think Ford being the high quality bragging truck builder that they are would do something about this situation. This issue could really put the hurt financially on a person.

- , Beech Grove, IN, USA

problem #38

Aug 202015

F-150 XLT 5.4L V8

  • Automatic transmission
  • 70,000 miles

Found a method online for removing the plugs in 2004-2008 Ford 4.6/5.4L V8 engines: https://youtu.be/iIQevez-DG0


Interestingly, you need to have: -thorough fuel injection cleaning to clean out the carbon in the combustion chamber -the engine somewhat warm -soak the plugs in carb cleaner -use an impact wrench to back out the plugs, the vibration actually breaks free the carbon deposits

Ask your local garage or trusted mechanic to check it out.

- , Clifton, NJ, USA

problem #37

Jul 012015

F-150 FX4 5.4L

  • Automatic transmission
  • 83,358 miles


I tried to get these plug replaced at two auto repair shops and they would not touch this 2006 F150 5.4L, because the plugs break off and they are a pain in the ASS to remove. So I had to go to the Ford dealership to have these plugs replaced and I was told that they have not had one of these trucks, that all the plugs have came out they have had from 1 to all 8 of the plugs break off and the repair would not be cheap. I drop my truck off tonight 8.13.15 to have the repairs done on 8.14.15. Wish me luck, I think I am going to need it

- , Peterstown, WV, USA

problem #36

Mar 282015

F-150 5.4L

  • Automatic transmission
  • 82,193 miles

I took my 2006 F-150 in for a tune up was told that 4 out of the 8 spark plugs broke off when the mechanic was taking them out. He has to use a special extraction tool to remove the pieces that broke off. The total cost of this Tune Up was $1,321.80!!!! This is absolutely unbelievable and I am outraged. Why wouldn't the manufacturer fix this problem as I see it is happening to countless numbers of people out there. There is a class action lawsuit regarding this:


Good Luck!

- , Mount Arlington, NJ, USA

problem #35

Jan 102015

F-150 XLT 5.4L

  • Automatic transmission
  • 117,655 miles

I was planning on taking a couple hours to change spark plugs. What a mess this turned out to be. Not only did every single plug break, I had to spend $100 on a special tool to remove the broken piece. The plugs themselves cost me almost $115.

I work for an OEM of another company. I know for a fact that certain mileage tests are required, be it 36,000 all the way to 150,000 miles, and in between. There is time before a certain model launches that corrections can be made. They absolutely knew this was a piss poor design and did nothing about it. It took me almost 13 hours to get these replaced. Not only did many break off, others had the metal shell slip off that the socket is supposed to grip. The electrode stayed together and I almost never got them out. What a f#*king nightmare.

Now I have to deal with another design flaw, the passenger side exhaust manifold. I have been a Ford fan, largely in part because they did not take any bail out money back in "08". I have owned 8 Fords in my life. After this exhaust manifold gasket replacement, I am getting rid of the truck and shopping elsewhere. No wonder they are about to lose their #1 position in truck sales. It's what happens when you don't take care of issues.

- , Seymour, IN, USA

problem #34

Jan 052015

F-150 LX V8

  • Automatic transmission
  • 124,000 miles


2700 dollars for tune up on a 2006 ford because plugs broke off. now where is ford on this? this sure is not a working truck for a working man. they need to help with this or it is the last ford I will ever buy.

- , Doss, TX, Pacific Islands (US)

problem #33

Aug 292014

F-150 FX4 5.4L

  • Automatic transmission
  • 46,603 miles

$1000 for a tune-up. 4 of 8 plugs broke, requiring 4 hours of Ford shop time at our North Vancouver shop.

- , West Vancouver, BC, canada

problem #32

Mar 032013

F-150 Supercrew Xlt 5.4L Triton V8

  • Automatic transmission
  • 100,300 miles

Ford knows about the defect in the design that causes the plugs to snap off , which causes the extra cost for me , the customer ....yet ford refuses to take any responsibility for their flawed design or product that doesn't meet expectations for a truck I paid good money for when I spent 35k for it new in 2006, so now I will drive it to it dies and the next truck I buy with not be a ford. Simple way to lose a customer FoRd! Buy the way, my wife wants a new 2014 Ford Edge Limited so bad right now, they ride so nice , we even test drove one......but because of a bad taste still in my mouth from this and other issues yet from my 06 ford f150 , my wife will be looking at the buick enclave if I got anything to say about it. Especially since we had 72 mos at 0% thru ford in 06 & now ford only approved us for 0% for 48 mos.......bye ford !

- , Wabasha, MN, USA

problem #31

May 212013

F-150 LX 5.4L

  • Automatic transmission
  • 90,000 miles

They said it was # 5 plug, replaced the plug and coil wire. Just drove it and still doing the same thing not fixed at all

- , Reidsville, NC, USA

problem #30

Feb 102013

F-150 5.4L

  • Automatic transmission
  • 82,000 miles


Started having a miss so i thought that idle have the plugs changed. 6 out of the 8 broke off. . this problem is total bullshit. first there should be a recall on it and it shouldn't cost so damn much to have it done. im $400 in to it now and still trying to get the broken pieces out. why hasn't ford motor company fixing their problem that is costing there customers so much time money and grief. you would think they would want to take care of this to have repeat business . i can tell u now ill never buy another ford

- , Sardis, OH, USA

problem #29

Aug 162009

F-150 XLT 5.4L V8

  • Automatic transmission
  • 63,000 miles

Truck started missing. Broke 7 out of 8 plugs. Had to special order removal tool. All in all, total repairs cost $750. Royal P.I.A.

- , Mobile, AL, USA

problem #28

Oct 232012


  • Automatic transmission
  • 116,196 miles

I searched for this problem on the Internet and found a site called fordproblems.com that states that this is a known problem and that Ford does not acknowledge it. They say that this is caused by untrained people not installing plugs properly.

The problem with that is that I bought my truck brand new and have had all repairs and maintenance done by Ford dealers. I challenge Ford to look at the service record for my truck and to talk to the service people. They will tell you how anal I am about fixing everything that goes wrong on my truck.

I treat my truck with respect. Anything that goes wrong on it I fix immediately.

Overall I have been happy with this truck but I am at a point to get a new one. This problem could have caused a fire. I am deeply troubled as this does not appear to be an isolated incident.

I ended up here because that is what http://www.fordproblems.com/problems/spark-plug-ejected-from-engine.shtml told me to do. I am following their recommendation. I am also in the process of reporting it to Transport Canada. If you are in the same boat the number to call is 1-800-333-0510. It took me a couple of other calls to the government to get this number. Chances are that you will have to leave a message to call you back.


- , Fredericton, NB, canada

problem #27

Oct 292012

F-150 XLT 5.4L V8

  • Automatic transmission
  • 105,000 miles

I have NOT attempted to change my plugs yet, and not sure I want to. I have a miss, but it is not bad. After reviewing all of the complaints here, I did a little searching for an official Ford response, but did not find one. I did find a class action lawsuit (http://www.lawyersandsettlements.com/blog/tag/ford-f-150). I have NOT looked into this, so not sure if it is worth it or not. But I plan to research the class action lawsuit BEFORE changing my plugs. If there is a way to recoup losses it is worth changing the plugs and driving the truck for another 100,000 miles. If there is no way to recoup losses, I may just sell the truck and buy another one. Hate to do that, but not worth $2000 to $3000 to change the plugs in a truck.

- , Brimingham, AL, USA

problem #26

Sep 222012

F-150 XL 5.4L V8 Triton

  • Automatic transmission
  • 104,000 miles

After replacing hundred of plugs I have never come across this. Who would have thought to research how to replace spark plugs. This is a common practice, or so I thought. As soon as the first one broke, I stopped and researched. I am not replacing a piston. Standard maintenance should not require taking out a new mortgage. Recall is definitely a must.

- , Clifton Park, NY, USA

problem #25

Aug 182012

F-150 Lariat 5.4L 3v

  • Automatic transmission
  • 106,000 miles

Ford has an issue with spark plugs breaking off when removing them. Some folks are lucky to have minimal plugs break off. I was lucky as I only had one plug break off. Luckily a local garage was able to extract the piece. I've heard others been less fortunate. When the piece fell into the engine and it cost several thousands of dollars to remove them. This is an issue that Ford needs to take responsibility for and recall the trouble vehicles and replace the plugs with one piece plugs. They will when the class action lawsuit gets initiated.

- , Glennville, GA, USA

problem #24

May 092012

F-150 XLT 5.4L V8

  • Automatic transmission
  • 100,000 miles

Its not fair to the Ford fans they need to recall on all the 2006 ford f150 cause it costing too damn much money to fix.

- , Columbus, GA, USA

problem #23

Mar 072012

F-150 XLT 5.4L V8

  • Automatic transmission
  • 100,571 miles

I took my 06/F150 in for a "tune-up" at 100K and I was told of the spark plug problem, but my mechanic said it only happens about 16% of the time, roughly 1 out of 6. The original estimate for the tune up was around $400. BUT then the call came.....two spark plus had broken, even after spraying them with break loose and letting the vehicle sit over night. Now my $400 tune up was going to be a $3000 Head removal. My mechanic worked with me and reduced the cost to $2,500......over 6 time the original estimate......I'm seriously thinking about taking Ford to Small Claims for the difference between the original tune-up and the final cost. Unfortunately, it's things like this that make me want to change from Ford to Chevy or Toyota, after being a Ford driver for over 35 years.

If Ford knows of the problem with the spark plus, this should have been a recall repair, instead, I had to spend nearly 8 months of payment on this design blunder.....THANKS FORD!!!!!

- , Aliso Viejo, CA, USA

problem #22

Mar 192012

F-150 Xlt Lariet 5.4L

  • Automatic transmission
  • 73,039 miles

Over $600 for spark plugs. This is absolutely ridiculous. I think Ford needs to be sued for not doing anything about this problem. There is no reason it should cost so much just to put spark plugs in your car or truck.

- , Cohutta, GA, USA

problem #21

Mar 082012

F-150 5.4L

  • Automatic transmission
  • 140,000 miles

i have a 5.4 f150 never had any trouble with it until now. i never knew that they would put these defective plugs in new trucks. i had one plug go bad so i knew it was time to change them. i didnt do much research cause i had a manuel. when i bought the new plugs i was wondering why they had an extra metal top to it. but i didnt realize so many people were having them break off. mine was # 8 so it was just a pain to get at in the first place but as soon as i get it loose an pull it out i realize i broke the head off called my normal mechanic and he tells me that he doesnt have the proper tools and i better take it to a dealership. i dont know about u guys but i go to school with a full time job. i was expecting 200 to 300 now i find out it could be thousands if the rest break off its just unbelievable. why havent there been a recall on something so major

- , Fort Smith, AR, USA

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