On certain Ford engines some of the spark plugs break off when removing them. Thus costing the consumer uneccessary expenses due to defective parts. The spark plugs are due to be changed after the warranty has expired so the manufacturer does not want to honor any claims.
I've been in a similar situation myself where my spark plug actually blew out of the top of the cylinder. The problem lies in the relatively few threads built in to the cylinder head and the fact that the heads are made out of aluminum in many cases. Practically speaking, the answer to your question is that this sounds like an unfortunate cost associated with vehicle ownership. Many cars come with design flaws that make them less comfortable to drive, more costly to repair, more expensive to maintain, etc. And, most people expect that parts in a car are going to wear out over time, especially parts that are supposed to be changed like spark plugs. However, filing suit against such a large corporation for something like this probably doesn't make sense. Could you file suit? Sure, but you'd just end up wasting a bunch of time and money. The better course of action may be to call your local dealer, or the dealer you bought the car from, and express your displeasure with the situation. Perhaps they will give you a deal on the repairs.
Depending on your vehicle, you may be able to participate in a class action that has already been filed this year against Ford Motor Company for the problem that you are complaining of with the spark plugs. You should consult with an attorney to determine whether you are part of the class.
The cost to sue Ford would amount to thousands of dollars more than the cost of replacing your spark plugs.
DISCLAIMER: David J. McCormick is licensed to practice law in the State of Wisconsin and this answer is being provided for informational purposes only because the laws of your jurisdiction may differ. This answer based on general legal principles and is not intended for the purpose of providing specific legal advice or opinions. Under no circumstances does this answer constitute the establishment of an attorney-client relationship.
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