Using the square drive option to remove 6.0L secondary fuel filter caps is risky and we recommend that do-it-yourselfers and technicians stop using the 1/2" portion to take the secondary filter lid off. Instead use a 24mm socket on the hex to remove and install the cap and always replace the o-ring seal on the cap with the new one that comes with the filter and apply clean engine oil to the seal and threads.
The issue is that over tightened and stuck lids will cause the square drive to split the cap making it extremely difficult to remove. Using a Ford 4x4 front hub socket or a similar spanner socket is a safe method of removing the cap once it is damaged and will also prevent damage to the filter housing that is possible when using other methods to remove it such as using pliers or a hammer and chisel. Let's take this step-by-step.
Place the spanner socket centered on the filter cap. If you are using a socket other than a Ford 4X4 socket ensure that it is similar in size to the one in this picture. Too large of a socket may cause damage to the housing in the next step. Mark the position of the lugs with a paint pen or light colored marker. In the picture below you can see the center of the cap is broken off.
Measure the lugs on the spanner wrench and select a drill sized slightly larger and carefully drill out the 4 positions marked on the cap. Allow the drill to go deep enough so that the lugs on the spanner socket protrude as far as possible into the holes to provide a good grip. It is okay to to drill completely through the cap but do avoid drilling down into the filter. Any shavings that fall thru will sit on top of the filter and are easily retrieved once the cap is removed.
Place the spanner wrench on the filter cap with the lugs inserted into the holes and using a ratchet wrench or breaker bar and loosen the cap. Remove the filter and any plastic drilling's that may have fallen into the housing. As always inspect the stand-pipe for damage and the bottom of the housing for debris and parts from old filters laying in the bottom. Install a new filter and a new cap applying clean engine oil to the rubber o-ring and threads. This is important! Tighten to 10 lb-ft or 14 Nm.
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