4.6L 3V Plug Problem and Lesson Learned.

That is amazing.
I have seen some poor quality control, but a total lack of seems to be the case here.
I would contact Champion right away and be askin some questions.
I really doubt (or hope) they would not want to put out a product like that.
Thanks for the warning.
Let us know what type of response you get if you do.

I only wish I had read this sooner. I decided to change the plugs on my '06 Mustang GT at 46,000 miles to avoid future problems. The first plug broke, leaving half stuck in the head. I had the car towed to the dealership, where they broke 5 of the remaining 7 while attempting to extract them. After 6 days I was expected to be pleased when they told me they were able to extract all of the plugs without removing the heads. I was then presented with a bill of $1,119. To add insult to injury, they reinstalled the same two piece plug.

It seems like the 2 piece plug isn't the main problem. It's the fact that Ford was too cheap to put anti-sieze on the threads.

Originally Posted by bassman97

It seems like the 2 piece plug isn't the main problem. It's the fact that Ford was too cheap to put anti-sieze on the threads.

Actually the problem is carbon buildup between the plug extension and the hole wall it goes through.
I have my doubts about anti seize actually helping the problem.
Best bet is to remove the plugs every 10 to 15k.
Time will tell.
Ford redesigned in 2007.
No more extension.

But it seems like by the descriptions of it squealing on the way out, that that has an effect on it.