The insert driver (Roll form tap) seats the insert
and completes the bottom threads.
This pushes the pin out to contact the threaded
hole. Back out of the insert is prevented by the
cam lock effect of the pin. This is an example of a step by step repair.
(1) Start the step tap into the hole to be repaired.
(2) Use the wrench and tap new threads. Continue to tap through
until the cutting edges are approximately 1/4 inch below surface.
(3) Leave the step tap in the hole and place the seat cutter over the shank.
(4) Using the wrench rotate the seat cutter. After a few turns lift the seat cutter
to inspect the seat. Repeat operation until the seat is completely cleaned up.
Back the step tap from the hole thus removing any burrs from the top thread.
(5) Make sure the hole is clean and dry, Screw the insert
onto the prepared hole.
(6) Lubricate the insert driver tool, Using the provided wrench rotate
the driver through the insert. When the insert is seated the driver
will tighten up, With increased pressure continue to rotate the driver
until it loosens up, Then back the driver tool out of the insert.
(7) Repair is complete. Solid steel threads are square to the
reconditioned seat, insuring a good spark plug seal.
The repair of spark plug holes can be done without removing the head providing
you have enough room to access the tools in the kit. Grease should be applied
on the flutes of the tap in order to catch chips from droping into the motor, repeat
this process several times with the grease to prevent any stray chips from falling
into the motor. You will want to blow out any loose chips by removing all spark
plug wires (so engine will not start). Then turn the motor over to blow out any stray chip.
Well I see there has been some additions to this post. I just wanted to let you know that I replaced all 8 holes with Timeserts in OCT of 2003, well we are now into 2005 and 35,000+ miles later I still have not had an issue with Plugs. I still hope Ford recalls the heads but untill then I am glad for the engineering intregrity of Timesert. They have a great product.
Built by FORD
Re-Engineered to be tough by ME!
98 Expedition XLT 4x4
Ceramic Pads on all 4 corners.
Moog balljoints and tierod ends
Bigsert inserts on all 8 plug holes!!
Bosch O2 sensors
Ported and reworked heads and intake.
I had that happen to me in late June. #3 plug, pass side, did the old escape pod routine. After paying for the repair where the dealer put an insert in to the head, everything seemed fine and dandy. Just this week, I had a problem with the #3 cylinder and took it back to them. Found out that the plug melted, the insert came out wrapped around the plug, and that possibly the valves are burnt. I looked online and found that if a stainless insert is put in, it will not stay in. You have to use an anodized aluminum insert. Now, Ihave to gather a whole crapload of info so I can walk into the service guy's office and show them that THEY screwed it up and will be paying for the repair, not me as now they are looking into removing the heads anyway.
I'll keep y'alls posted on what happens next, after I call the Ford home office
There is no choice BUT to do the inserts to fix this??? I have a buddy with a 99. Just lookin out for him. This is the first I had heard of it BUT I always am looking at the "old iron" section or the "diesel" section.
My 02 F150 Harley Davidson edition blew a spark plug out of the #2 cylinder. I have been going round and round with Ford about this. The customer service line is useless. I tried them and they told me Ford is doing nothing to fix this problem. I emailed the consumer affairs manager at Ford. Her name is Rosemary O'Malley. She had Lynne Buckman from the Corporate offices of Ford Motor Company call me. She offered to pay me back for the parts of the fix, which added up to a whopping 125.00. She claims that this is not a common problem. My bill was 500 bucks for the heli coil fix. I was told by my local dealership that the heads are $4,000 to replace. Lynne told me that it would be a waste of my time to write a letter to the CEO of Ford Alan Mulally because he would send it right back down to her. This is not right. The heads need to be recalled and people who drive the F series vehicles should be able to drive their vehicles with confidence. These are their direct numbers...
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