Three Valve Ford Triton Insert Kit
Contents
1. ATD 5410 Three Valve Ford Triton Insert Kit The Three Valve Ford Triton Insert Kit will repair the threads in cylinder heads that have broken spark plugs in the following engines of the Ford family 3 valve 5 4 L and 6 8 L engines built before 10 9 07 and 3 valve 4 6 L engines built before 11 30 07 found in many 2004 2008 Ford Lincoln and Mercury vehicles Not intended for late production 08 models and up as they may use a special M12 x 1 25 Taper seat plug Tools required for this repair include Three Valve Ford Triton Insert Kit JB Weld or similar product Air Gun Quality Air wrench Borescope Spark plug socket and extensions Shop rag Bearing grease Safety Glasses Ensure all broken parts of the spark plug are removed Use bore scope to determine that the cavity is clear of all debris or broken plugs Insert guide into the spark plug chamber Coat Core drill with bearing grease and insert into guide Make sure E clip is securely positioned on Core drill This is a critical step in this procedure to ensure proper positioning of the new insert See Illustration 1 CAUTION WEAR SAFETY GLASSES Using a good quality air wrench carefully and slowly drill until E clip touches top of guide Slowly remove Core drill Most if not all shavings will be removed once the Core drill is removed Use an air gun to blow out any remaining shavings CAUTION ALWAYS WEAR SAFETY GLASSES WHEN BLOWING OUT THE CYLINDER Remove E clip from T2. must be attached to drill to prevent damage to spark plug seat Illustration 1 Illustration 2 Illustration 3 Core Drill with Tap with E Clip removed Tap with E Clip in place E Clip stop in place for insertion into guide Ready to tap new threads Page 2 of 2 PARTS LIST ATD5410 Ford Triton 3 Valve Repair Kit 389 200 Reamer Core Drill 393 400 Guide 3 Valve Tool 393 300 Tap 3 Valve Tool 393 200 Insert Plug ATD 5412 Insert 3 Valve Tool 393 900 Blow Molded Case
3. ap See Illustration 2 Coat Tap with bearing grease and insert Tap through bottom of guide until tap threads are completely inside guide Replace E clip See Illustration 3 Warning Failure to replace E clip can result in cylinder damage Insert Guide Tap assembly into spark plug chamber Using the air wrench carefully and slowly tap until E clip touches top of guide Most if not all shavings will be removed once the tap is removed Remove Guide Tap Using an air gun carefully blow all debris out of cylinder CAUTION WEAR SAFETY GLASSES Use bore scope to make sure all debris is removed from the cylinder Screw insert on the Insert Plug Soread JB Weld or another heat resisting metal bonding agent on the outside threads of the insert Do not use a quick setting product Using a ratchet and extension screw insert into new spark plug threads Tighten insert until snug With a quick left turn of the ratchet break the Insert Plug free from the insert Use caution that you do not also turn the insert You may also allow bonding agent to cure prior to Insert Plug removal The insert is now a permanent part of the head Using the appropriate spark plug socket screw spark plug into new insert and torque to manufacturers specifications Allow bonding agent to fully cure before running engine Reconnect coil and boot The job is now complete Page 1 of 2 Three Valve Ford Triton Insert Kit E Clip must also be re attached to tap E Clip
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