Ford Expedition lean codes could caused by a leaky PCV hose.

If a car has a check engine light on and has P0171 and P0174 codes stored, the most likely cause is a vacuum leak. These codes are set by the car’s computer when it sees too much oxygen in the exhaust. Excessive oxygen readings in the exhaust will set lean codes. This does not mean that the oxygen sensors are defective. It is a common mistake for people to replace oxygen sensors when lean codes are present. Just because the code is related to oxygen sensor readings, it doesn’t mean that the oxygen sensors are bad. If both of these codes are stored this means that both banks of the engine have excessive oxygen in the exhaust. If the oxygen sensors are replaced it’s most likely that the same codes will reappear. It is very uncommon for two oxygen sensors to fail at the same time.

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Mode $06 misfire information displayed

Misfires particularly in Ford cars and trucks can many times be identified before a misfire code sets and turns the CEL (Check Engine Light) on. This is a huge time saver, especially when there is a definite misfire felt but the code seems to take forever to appear. Fords take a long time in some cases to run through it’s necessary drive cycles needed for self testing. Auto technicians deal with this common problem of diagnosing misfires on Ford vehicles with no codes set by using Mode $06. Usually only manufacturer specific scan tools will display misfire data when there’s no code, but OBD 2 generic scan tools that can access mode 6 on Ford vehicles can be a great help.

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2005 Ford Expedition TPM reset procedure requires a magnet

© DenlorsTools.com – Reset Magnet for sale. Summary: In this auto repair blog post we outline the TPM reset procedure for the 2005 Ford Expedition, first allow me to explain a little about how Tire Pressure Monitoring systems work. TPM (Tire Pressure Monitor) systems are either direct or indirect. The 2005 Ford Expedition uses a direct tire pressure monitoring system. It has sensors that measure the exact tire pressure in each tire (this can also include the spare). The tire pressure sensors are incorporated into the metal valve stems on the Expedition, they transmit the tire pressure information to the ECU (Electronic Control Unit). TPM sensors have a battery that only last so long and will eventually fail over time like any other battery. TPM sensors are not serviceable, so when the battery goes bad the TPM sensor has to be replaced. If a tire is low and the TPM system is working properly, a warning will be displayed on the dash alerting the driver. The tire pressures should be checked as soon as possible to avoid damaging a tire beyond repair. Tire change mechanics must be careful when changing tires with TPM sensors because tire machines can easily damage a sensor. Fix a flat tire sealer or a similar product can also damage the sensors.

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Expedition body is raised for easier cylinder head removal.

Summary: If removing a cylinder head on an Expedition or Navigator, many professional technicians will do a “Body Off” procedure which makes the engine much more accessible. Although this appears to be over dramatic and an over-kill, it really doesn’t take that long to raise the body once you know what to do. Flat rate technicians make their money by getting the job done in the shortest period of time. And if that means seemingly going to extremes, so be it! Find out how to avoid going through all this trouble for a failed helicoil, by clicking here.

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Calvan 11/16″ drill bit used with air ratchet and 1/2″ socket.

DenLors tools has sold hundreds of the Calvan spark plug repair kits and has had no reported failures. We’ve answered many questions about Ford spark plug thread repairs over the last couple of years and have included them in various places on our site. Now in this auto repair blog ALL of the frequently asked questions to date are posted here in one central location, if you don’t see your question answered, feel free to use the comment form and ask. Included here are questions about repairing spark plug holes after Lisle, Napa, Auto Zone, or other brands may be thicker than the Heli-Coil, but still have managed to fail and allow the spark plug to blow out AGAIN. We are not out to discredit any other spark plug insert company, we just know from our customer feedback what works and what just works for awhile. The questions below answer questions from real customers with this serious problem. We recommend the Calvan Ford spark plug insert repair kit as the best solution for Ford 1998-2004 4.6, 5.4. 6.8 SOHC (2 valve) engines, the following will help show why.

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If  Ford’s poorly designed spark plugs would just all come out like these.

© DenLorsTools.com Lisle Spark Plug Extractor DLT  Summary: The lucky guy that removed the spark plugs in the picture above, has someone watching over him, he narrowly escaped huge spark plug problems. We have orders everyday for specialty tools to remove broken spark plugs from Fords. The two piece spark plug typically comes apart, separating the main part of the spark plug from the huge electrode shield. Ford’s spark plug design comes under the heading “what were they thinking?”. 

DenLors Tools was one of the first automotive tool suppliers to sell the Rotunda 303-1203 specialty tool that was recommended in the Ford TSB to remove these broken spark plugs when they were broken upon removal. Now, we have a much better solution in the LIS65600. The Lisle specialty tool has quickly became our most popular tool for removing Ford broken spark plugs. We have had only positive feedback from auto techs that have used this tool. Ford forums have recently been helping to spread the word of the success of this new tool. There is quite a buzz about a Ford class action suite regarding this poorly designed spark plug, but our role is to help those that are dealing with broken spark plug problems, to remove them as quickly and inexpensively as possible.

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See the quality difference in the Heli-Coil (top) & the Calvan (bottom)

© DenLorsTools.com Summary: In this automotive repair/tool blog we cover Ford spark plugs blown out of cylinder heads, it’s still a huge problem. To date we have sold hundreds of Calvan spark plug thread insert tool kits and have had no one call back to say it was too hard or it didn’t work. The included video makes the spark plug insert repair easy to understand and answers all the questions about how this job can be done in the vehicle saving thousands of dollars. We are commonly asked if the Calvan spark plug repair kit will work after a Heli-Coil or some other thin, weak repair has failed and have blown out AGAIN. The answer is yes, Calvan inserts are much thicker than the competitor’s inserts and will work much like an over-size oil drain plug will work in a stripped out oil pan. Since the Calvan insert is not just a coil of wire like the Heli-Coil it is much stronger. And since the Calvan insert is thicker than the Heli Coil, most times it can be used when the Heli Coil is spit out.

Our customers tend to research their options to find the very best solution for this very frustrating problem, that’s why after they research Helicoil we know most will ultimately purchase the Calvan Ford Spark Plug Insert Tool Kit.

Our Automotive Tech Article on Ford spark plug blowouts, goes into much more detail about Ford spark plug problems, including the fact that when buying a rebuilt head the consumer should be aware that it may have an inferior repair insert already installed. That’s why it is our recommendation to repair the cylinder head you have with the Calvan insert tool kit, so you know that you have a strong, long lasting repair that you don’t have to worry about.

Question: How long will the Calvan spark plug repair last?

Answer: The Calvan inserts are designed to last the lifetime of the engine and are stronger than the original threads.

Question: Time Sert says “The only 100% way to know the valves are not open is to remove the valve cover and inspect the cam, making sure that it is not depressing the valves on the damaged spark plug hole.” Do I have to remove the valve cover with the Calvan Ford spark plug insert tool kit?

Answer: No. The Calvan tool kit allows the mechanic to verify valves are closed with an included cylinder leak detector. Plug the rubber stopper from the leak detector into the spark plug hole with a low amount of air from an air compressor going through the hose. The rubber cone will pop out of the spark plug hole when the valves are closed. The video shows this as well.

Question: How do I know all the aluminum metal shavings are out of the cylinder?

Answer: A borescope is used to make sure all foreign debris is removed. A video scope can be used as well, we have fairly inexpensive video based scopes that in our opinion, are better and easier to view.

Question: I’m afraid I might start drilling or tapping the hole crooked, am I going to damage my head beyond repair?

Answer: With the Time Sert, the tap has a small pilot at the end of the tap. With the Calvan specialty tool kit (since it is made specifically for Ford 4.6, 5.4 and 6.8 Triton engines) has a guide that fits into the spark plug well to perfectly guide the drill and the tap making the repair centered even in hard to access areas.

Question: Will my spark plug be properly grounded through the engine, since the insert will have JB weld on the threads?

Answer: I’ve only had one person ask this. The answer is yes. JB weld or Loctite with some other brand inserts is being used on the threads, but there is a large enough percentage of metal to metal contact that provides ground, to allow proper firing of the spark plug.

Update 12/01/2011

Time Sert 51459 Inserts in the image below. Notice they are more than just a thin coil of wire.

The Calvan 38900 is for spark plug ports on Ford Triton SOHC 4.6, 5.4 and 6.8 Liter 2 valve engines – 1998-2004. The Time Sert repair kits are made for much more than just the above application. DOHC is not a problem with the Time-Sert 5553. Time Sert makes a kit that will work on most vehicles. This fact has saved our customers a lot of money. Time-Sert’s comprehensive coverage doesn’t stop at “spark plugs”. They make kits for head bolts, main bolts, drain plugs and the list goes on. The Time-Sert inserts are bushing type and NOT just a coil of wire like the Heli Coils are. We have sold tons of the Time Sert kits with no problems reported as well. Still have questions on your application? Feel free to give us a call.

Linking: Please reference this car repair article when quoting, linking to this page is welcomed and appreciated. If you are new to linking a page. 1. Left click the link; to highlight 2. Right click, select copy 3. Right click and paste to car forums, auto repair blogs, car repair web sites etc. Thanks! Disclaimer: Automobile repair tips are designed for informational purposes only, without warranty of any kind, in no event shall the author of this site be liable for any consequential, incidental or direct damages sustained in the course of using the repair information in this article. All rights reserved by DenLors Auto (Automotive specialty tools /Car mechanics Tools). Keep us in mind for auto tool needs, shop supplies and mechanics equipment. 

Related Links and Products

Ford Spark Plug Blow Out Problems How to Repair Original article

Calvan 38900 Insert Kit – Product in this blog for sale 

Calvan 389-100 DLT Inserts – Additional inserts sold separately

Expedition Cylinder Head Removal w/Body Off NOT required with the 38900 DLT see what you’re missing

New Specialty tool for handling Ford broken spark plugs!

© DenLorsTools.com If you’re a subscriber to our automotive tool blog, you know we pointed out in a previous post, the need for a less expensive alternative to the Ford Rotunda 303-1398. The SPX Rotunda 303-1203 removes broken spark plugs on some Ford 5.4 engines, 2004 and up. But it only works after the broken porcelain piece is out of the way. That’s where the new Lisle LIS 65600 automotive specialty tool, comes into the picture. The best way to try to prevent Ford spark plugs from breaking to begin with (per a Ford Technical Service Bulletin-TSB) is to loosen the spark plugs slightly and then soak them with penetrating oil. Sometimes the carbon build up around the electrode shield will still separate from the main part of the spark plug. So, in many cases the porcelain part of the spark plug will stay in. This prevents the use of the 303-1203. Rotunda offers the SPX 303-1398 to remove the porcelain or ceramic piece, but the pins included in this six hundred dollar kit can only be used once. The pins are secured into the center of the broken spark plug (where the electrode was) with loc-tite, then the puller is used to hopefully pull the ceramic piece out of the way, so the two hundred dollar 303-1203 can be used to remove the metal electrode shield.

Lisle’s Method, using the LIS65600 auto specialty tool implements a different approach. First, if the broken porcelain is stuck down in the spark plug hole, the first part of the Lisle kit is used to press it down a little further without breaking it.

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This picture shows some side dash bolts with trim removed.

© DenLorsTools.com Summary: Common cause of 2002-2005 (Third Generation) Ford Explorer and Mercury Mountaineer low airflow issues covered. Broken recirculate doors can affect airflow from the blower fan if the main air inlet door has fallen. A Ford Explorer that has a full charge of refrigerant and is cooling, but is not quite cool enough may have a broken fresh air door, preventing proper recirculation. The fresh air door is also called a recirculate door, max air door or main air inlet door.

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Some of our most requested tools lately has been specialty tools for aligning cams and cranks for timing chain alignment. In the past changing a timing chain or timing belt only required basic tools to get the job done. The camshaft and crankshaft sprockets only went on one way due to the design that used a key-way which only allowed the pulley to go on one way. Alignment marks for the cam and crank were aligned per directions from the service manual. Now many engines have no key-way and the pulleys are pressed on. Since the key-way is not used in increasing number of vehicles, specialty automotive tools are required to properly Align the cam and crank.

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