My buddy Martin just posted this on a Lightning board I frequent.

TSB 07-15-2

5.4L 2V AND 6.8L 2V MODULAR ENGINE SPARK PLUG THREAD OUT OF WARRANTY REPAIR PROCEDURE FOR ALUMINUM HEADS

FORD: 1997-2000 F-250 Light Duty
1997-2003 F-150
1997-2004 Expedition
1997-2007 E-Series
1998-2004 F-53 Motorhome Chassis, F-Super Duty
2001-2005 Excursion
LINCOLN: 1998-1999 Navigator


ISSUE:
Various 1997-2007 vehicles with a 5.4L 2V, or 6.8L 2V engine with stripped or missing spark plug port threads in modular engine aluminum heads. Ford Motor Company now authorizes LOCK-N-STITCH aluminum inserts and tool kit.

ACTION:
Follow the procedure included in the tool kit for using the tools and inserts. Tool kits and inserts can be ordered from Rotunda by calling 1-800-Rotunda (768-8632). Choose option two (2), number 302-00001.

NOTE: FORD MOTOR COMPANY HAS DETERMINED THAT REPAIRS MADE WITH THESE ALUMINUM INSERTS AND LOCK-N-STITCH TOOLS DO NOT AFFECT THE HEAT TRANSFER FUNCTION BETWEEN THE SPARK PLUG AND THE CYLINDER HEAD.

NOTE: THIS PROCEDURE IS NOT AUTHORIZED FOR WARRANTY REPAIRS AND IS THE ONLY FORD AUTHORIZED PROCEDURE FOR SPARK PLUG THREAD REPAIRS.

WARRANTY STATUS:
Information Only - Not Warrantable

I just figured someone might be interested in the prescribed way Ford is instructing their techs to fix the heads when a plug is launched.

Here is the Lock-N-Stitch website: Spark Plug Thread Repair Inserts

Stewart<!-- / message --><!-- sig -->

 

So what the plug is firing out of the hole?

 

I'm not trying to be a dick, so I hope I don't offend you, but using proper grammar when composing a post helps to communicate your thoughts.

I think you're asking if the spark plugs are being launched from the cylinder heads, correct?

If that is your question, then yes. This has been an ongoing problem with the Ford modular engines for years, up to the 2003 model year vehicles.

For the 2003 model year vehicles, Ford started using 8 thread spark plug holes in their cylinder heads. Up to that point, they had only been putting in 4 threads for each plug hole. Although at this time, there have been a number of cases reported by owners of '03+ year vehicles that have spit plugs too.

Here are some links for you to read that I've previously posted in other threads here on this board.

Feds Urged to Act on Ford Spark Plug Blow-Outs
http://www.consumeraffairs.com/news04/2005/ford_spark_plugs.html

Ford Engines - Spark Plug Defect
http://www.consumeraffairs.com/automotive/ford_spark.html

Ford Trucks Spit Spark Plugs
Ignored by Ford, Truck Owners Face Massive Repair Bills
http://www.consumeraffairs.com/news04/2006/01/ford_truck_engines.html

Any Lightning or Mustang forum will have a bunch of threads concerning this issue, if you do a search. Even the 6.8L forum on this board will have threads addressing this issue, since the V10's also have this problem.

Stewart

 

Sorry about the grammar problems. I'm not an english teacher. I spend most of my time in the old fords forums, (note the signature) so I don't hear of many modular issues. That sounds like a really crappy issue to have. Why didn't Ford warrant the Helicoil fix i wonder?

 

Neither am I, but I do have this:




I actually took note of that after I posted all that info!

Heliocoil actually sucks for fixing this issue. Timesert inserts have always been the preferred choice, but the all aluminum Lock-and-Stitch inserts have proven to be the best choice for the 4 thread spark plug holes.

As always, it comes down to money. If Ford has never admitted there is a problem with the modular heads, and they never will. Their standard line is that the spark plugs are improperly torqued.

They are correct in that, but think about it, most of us guys who work on these things are pretty much old school guys who go by the German torque specs of guden-tight, because we're used to having quite a few threads in the cylinder heads.

Ford HAS warranteed most claims, but I have read posts where people have complained that Ford refused to cover their plug spitting head.

Stewart

 

Edit: Post unneeded.

Stewart