Eventually, the truck will start to backfire through the intake and even fail to accelerate to over 30mph in severe cases. At the dealer, we generally see these trucks go a long time with this misfire condition. 5.4L 3v Catalytic Convertersīe wary of driving with this engine if you are experiencing a misfire of any kind. 2008+ Engines use a different design that does not break. More details are available in another article I wrote which include step by step instructions on Replacing the spark plugs on the 5.4L Triton at home. SP546 is the revised spark plug, the SP515 is the old one. This issue was fixed with an updated spark plug. They have extended sleeves that reside down inside the head that tend to break off because of possible carbon/rust build up. These plugs generally last around 100k miles but they are a bear to remove when you do go to replace them.
The situation is slightly ironic since earlier 2 valve 5.4L (97-03) tended to blow spark plugs out of the head but later 3 valve 5.4L (04-07) tended to break off in the head. Due to the design of the combustion cylinder the plugs needed to protrude down through the head to the combustion chamber. Each of these sensitive coils are placed upon a specialized spark plug that tends to break when removed. Spark plugs are a whole different animal on this engine. Even bad credit can get easy approval, but you could also try Capital One if your credit is a bit shakey. Get an easy $100 bonus if you apply for a Discover Credit Card. Repairing this stuff can get really expensive, but I can help. Avoid cheap aftermarket coils, only use Motorcraft DG511. Generally we diagnose the cylinders with the misfire and replace the spark plug and ignition coil for those cylinders. The ignition coils easy to replace though. It will cause a light jerk or bucking that some describe as a transmission issue. Symptoms of a failing ignition coil is cylinder misfires under load, accelerating, or most notably cruising up a small grade at arond 55mph in overdrive. The ignition coil can fail internally as well. The spark plug wells can also fill up with oil or coolant from nearby leaks causing the spark to short to the cylinder head. These deteriorate with age and weak spots in the rubber can cause the spark to jump to the cylinder head instead of the spark plug.
Most of the coil failures are actually because of the coil boot, the piece of rubber that covers the spring that touches the prong to the spark plug. Most trucks will need multiple replacements in it's lifetime. The general consensus is that this type of ignition system is the most efficient design offering independent control, but the coils do suffer from failures likely related to heat. COP systems are now very commonplace in the automotive industry.
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