i know what you mean justin.
but when you see several dead stockers also blow out plugs from the early heads and it's a known cause . one must take precutions when moded and recheck torqe from time to time.
i just today repaired my marina's owners 2000 f350 v10 it blew number 5 plug at 40 k dead bone stock. he now has ten updated inserts from time sert in his heads with the new plugs. and this was not easy for both of us. it is a s--k job. and the kit he would not tell me cost of other then the word given me "costly" still beat replaceing a head or 2.

 

It's a poor design, pure and simple.

While extra boost didn't help the case, it certainly didn't CAUSE it. Big difference.

If boost caused it, then my stock-block/heads 97 would have ejected all 8 of it's plugs at this point. I run 10.5 psi of boost on a motor that was never equipped with a factory blower.

Some heads have as few as 3 (most have 4) threads to hold the plug in. That's a recipe for failure.

Guaranteed failure? No.
Potential failure? Absolutely.

 

I have to agree with the poor design. Aluminum heads need more threads than iron heads to keep plugs in. Ford apparently tried to take a short cut and used short threads. I run 14 psi on my LeBaron with no problems, but it has 3/4" reach plugs and the holes are threaded all the way. It also uses washers rather than taper seat for sealing. The weak link on these is the head gasket.

 

most of the guys know i spent 42 years of my life in dealerships.most with vw/audi.some with toyota and ford as service directors. with both vw and toyota i also saw plugs blow out when improperly torqed in to the head .infact the first plug i ever saw blown out was a air cooled vw that had short plug threads and either inder tightened or over tightened plugs that pulled the threads.with the newer vw's i had guys come in modded and running 30 pounds of boost . never saw 1 long thread properly torqed plug blow out. but the early 4.6 .5.4 and 6.8 plus a few v6's oyes. i have fixed heads with inserts useing a real good kit works wonders even if ford dosn't want it repaired that way.the clinker is you hear something like a exhaust manifold leak before it happens.
heres the 2 real good kit companys and note the latest news in timeserts site about ford spark plugs and gm's statement about the solid thread bushing insert these to company make

http://fulltorque.com http://www.timesert.com

 

I'm with you man. They should have honored the warranty. I'm a tech at a Ford dealer and have seen many plugs blow out on everything from Crown Vics to E150s. On another subject, be careful with the stock rods, they can't handle much more than stock power.

 

One thing I forgot, do you know if the dealer got hotline involved? Did they have a Field Service Engineer come out and look at your truck? A dealer cannot deny a warranty repair unless hotline gets involved.

 

same with vw and toyota . hot line and the dsm most be involved for a warrenty deniall. and i had many vw's i wanted to cancell but could not as it was cheaper to fix then go to court. after the repair we simlpy said don't bother comeing back here your car will not be serviced, again against the law but usally worked. they would go else where and be thrown out.

 

the problem is the guy who started it on the 99 lightnin set the cnc machine to cut the holes 3threads too short for the plkug and this is why they blow my cousin has one and has had 4 blow out so he decided to take off the heads and helicoil them all.

 

there was 5 threads not enough for any threaded item in alloy. ever see a lawn mower blow a plug it happens to them also.
and now ford even has a newer style plug . the tappered seating area is at the bottom and threads on the top almost looks like a glow plug. and it has a 9/16 hex head on them.another new tool to buy.

 

I just bought a 2000 ford lightning and exactly one month from the day I got it the same thing happened to me. I was on my way home from work and the nuber 8 plug blew, luckily I had purchased an extended warranty that is going to replace my engine! Is there anything that can keep this from happening again? If not why won't ford do anything?

 

...Welcome brandon to Ford Truck Enthusiasts!


…..See you on the boards.

 

well if u are getting a new engine it will probably have the improved heads with more threads in them.


Dan.

 

Just make sure when they give you this new engine, that it is a L engine. That means forged crank and forged pistons with the lower CR. No cast pistons or cast cranks are supposed to be in L's.

 

I blew the #3 plug last weekend. I had the camper hooked up and was driving through town when BANG!!!!

I stopped at the Ford dealer (2 blocks from the BANG!)
The service guy said I blew a plug and that it was 4:30 on Friday and all the techs were headed home. He walked away without even offering to help. Thanks DENNY FORD!!!

I took it to a local shop and they put in a new plug. I hope it holds, but I am looking at the solutions that many have come up with (heli-coil etc).

I love my Expy, but 3-4K for heads makes me wanna cry.

 

Time-sert is the ONLY way to go. Do NOT use a regular heli-coil.