When did FORD fix the heads on the 5.4L? (Spark Blowout)

[Manipulator]

I have a 2003 Expedition with the 5.4L and am curious when Ford fixed the dreadful spark plug blow-out problem. I have heard the heads were bad all the way through 2003 and some 2004. Then I hear this is not true and the heads were redone after Oct 2002 so if your heads have a date of Oct 2002 or later you are fine. I have read thread after thread after thread with regard to this and no one, not one person has a definite answer. It seems so many people out there know someone who works for Ford and all of them have a different answer.

I just changed my plugs last Saturday at 69K and they needed it. I was surprised Ford says 100K as mine would have been about worn out by then. I would say 70-75K is the limit. I used the OEM plugs for replacements. It was a real PITA getting the back plugs out but overall not impossible. Some people said you need to remove the fuel rails but you don't. Or at least I didn't. My plugs were in there good and tight and it felt like the threads were coming out with them when I removed them. The threads on the old plugs looked fine though. I used plenty of anti-seize on the new plugs and they seemed to thread in nice and easy.

I looked on the side of my engine (drivers side) and there is a sticker on the lower valve cover that has some numbers on it and says 5.4L and a manufactured date of 12/03/03. So it looks like my engine is a late 2003 engine. I hope it has the newer heads.

[galaxie641]

'03s got 8 thread heads but there are still stories of them blowing out of even '03 heads but you have to believe the chances are reduced quite a bit with double the threads. That said it still all comes back to proper torque and proper change intervals, not the rediculous 100K Ford recommends.

[Manipulator]

Thanks for your reply. On the torque issue, I just snugged them a bit and then 1/4 turn. They felt pretty tight. It felt about the same effort as removing them. I know I know should have torqued them but I was afraid with the 1/2" torque wrench I had (only one I had and all the auto store had in stock). I don't think I could have got the the back ones with this.

I agree with the change interval. 100K is too long if you ask me. I almost went with Iridium but opted for OEM. Glad I did, I feel more secure with what Ford recommends. I think if Iridium was so great Ford probably would have used them considering what a PITA it is to change the plugs on their engines.

[Manipulator]

Another thing, I was reading that the heads were redone in Nov of 2002. I think I said October. I heard they used up the old heads on the the 2003 until they were all gone and then began using the revised heads. So you could have a 2003 5.4L with the older heads if it was manufactured in late 2002 and and early 2003.

Considering my heads say 12/03/03, which is over a year later, I would have to say my heads are probably the revised version. I hope they are. Pisses me off Ford wouldn't stand behind this and do a recall. I like Fords and I like to support American products and workers but next time I shop for another vehicle I may pass on a Ford. At least if I buy one I will investigate the model and problems first. When I bought my Expedition (used at 26K one owner) I had no idea this problem existed. If I would have known, I would have never bought it. It wasn't until like 3 months later I was treating a mechanic and we were talking about trucks; I told him what I had and he said "did you know those blow the spark plugs out the heads?" I was like WTF did you say? I researched it and couldn't believe it. He also said not to wait until 100K to change them, said that they have changed a few around that mileage and the threads came out with the plugs. He said 70-75K tops.

[LxMan1]

Small percentage compared to the millions out on the road!!!

[phil6608]

My 03 did NOT have the new upgraded heads with 8 threads!

[Manipulator]

Phil, look on the drivers side lower valve cover, I'm curious what the manufacture date is on the engine. Like I was saying, it possible your 03 was built in 2002 or early 2003.