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The 5.4 3v spark plugs broke off the extended tip due to carbon build up between the extended tip and the cylinder head. The carbon would basically "concrete" the tip extension into the head, causing it to shear off during removal. In fact I had one in yesterday. Depending on fuel quality, some areas of the US saw way more problems then others. Like JD said, the later years of 5.4 3v switched to the conventional spark plug/cylinder head spark plug hole design eliminating the problem. All Raptor 5.4's have the new design.


The 6.2 has a conventional design spark plug, and also twice the amount of threads. Both plugs fire on combustion for better flame front due to the 6.2's bore size. Previous dual spark plug engines (like the newer hemi), and even some single spark plug per cylinder engines fire the second plug/pulse on exhaust stroke to help emissions.


It's going to be hard (actually probably impossible) to find a OHC engine made by any manufacture in recent years that doesn't have spark plugs down in a well, its just part of the design.


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