ORLANDO, Fla. — It's a repair bill no vehicle owner expects -- $1,000 or more just to change spark plugs.
But some Ford owners have to pay that because their spark plugs break when being replaced.
Action 9's Todd Ulrich found in the worst cases, those broken plugs trigger total engine failure and a huge repair bill.
Ken Hansen faces thousands of dollars in repairs for his 2006 F-150 pickup, and he blames Ford and a problem with spark plugs that break when replaced.
Hansen said his engine failed a month after routine maintenance at a Ford dealership where two spark plugs broke off.
"I never even knew they had a spark plug issue,” said Hansen.
Many mechanics say it's common for spark plugs to break in eight different Ford models. Changing the plugs can cost $300 to $1,000.
In some cases when broken plug debris is left inside it can wreck an engine.
“I've got a horror story here because I've got a motor that is completely destroyed because of it,” said Hansen.
Hansen claims Ford would not help, so he turned to master mechanic Jay Zembower, who found spark plug debris had blown a hole in the piston.
Zembower found that repair caused the problem.
“It is a spark plug-related repair gone wrong,” said Zembower.
Hansen was told that replacing the engine will cost between $6,000 and $8,000.
Four years ago, Ford sent out a service bulletin to mechanics warning that spark plugs can break, so they should use special procedures to avoid engine damage.
The models covered include 2004 through 2008 F150s and 2005 through 2008 Mustangs and Lincoln Navigators.
Ford has called the broken plugs a routine maintenance issue.
Many repair shop owners, like Zembower, call it a serious design flaw.
“We had some where seven of the eight plugs broke off even after following Ford's guidelines,” said Zembower.
In its response, Ford said no manufacturer discloses all maintenance costs that could be higher than normal, and there's no safety issue to trigger a recall.
But Hansen says the manufacturer should be responsible for the spark plugs.
“That's the only thing it could be,” said Hansen
The National Highway Traffic Safety Administration has received at least 100 complaints from F-150 owners about broken spark plugs.
There is no federal investigation.
Ford issued the following statement to WFTV: "As vehicles become more sophisticated, it becomes even more important that proper repair and maintenance procedures are followed. Spark plug replacement is no exception. For this particular procedure, we have issued a Technical Service Bulletin, which describes in detail the process for changing the plugs and we have developed a tool that is readily available on the market to help technicians even further. Based on our investigation, there should rarely be a problem if this process is followed. We cannot speculate as to why some are still having problems completing the service, but we are aware of instances where problems occurred because the proper procedure was not followed. There is no safety or other issue that would justify a recall."
WFTV
