Step 8: Remove the old spark plugs.
*For best results, use the Ford OTC 6900 Spark Plug Socket; however, a deep socket 9/16 with a couple of extensions will work to remove the old spark plugs. Be careful and try to keep the socket lined up with the spark plug; this will decrease the chances of breaking the old spark plugs as they are extracted.
Begin working the plugs by turning them back to the tight position and loosen to the 1/4 turn position, each time going an additional 1/4 turn or so until they are out. Don’t get in a hurry and if it feels like they are trying to break or just not turning easy enough, let it soak a little longer. Repeat process for each plug. NOTE: do not use any more Carburetor/Choke cleaner at this point, Ford suggests not to overdo it, as too much fluid could cause the engine to Hydro-Lock.
Step 9: Install the new plugs.
*Check with your local parts dealer for Gap settings. I found for my application it was .045” NOTE: New plugs should be installed using a film coating of Motorcraft high-temp nickel anti-seize lubricant on the ground electrode shield. Do not coat the electrode strap.
Place a small amount of anti seize on the spark plug threads and the lower spark plug shaft below the threads. This will ensure easy future removals. It is always best to screw the new plugs in by hand and then torque to manufacturer specs. Plugs should be torqued to 25 ft-lbs according to Ford. Most mechanics I spoke with said 15 ft lbs is more than enough, especially considering the issues with removing the 2-part plug design. Repeat process for each spark plug.
Step 10: Re-install the coil packs in reverse order of Steps 4-6 above.
Step 11: Re-connect your negative battery terminal and make sure you have not left any tools under the hood. Re-tune your favorite radio station and go for that test drive you have been working towards.
If you are unfortunate enough to have a plug break, it’s not the end of the world. Go to your local parts store and get the 3V spark plug extractor for broken spark plugs. Most auto parts stores rent these extraction kits and they are fairly easy to use. http://www.youtube.com/watch?feature=player_detailpage&v=A3MPAPXBB6Y