Spark plugs blown out of engine block?
 

I was researching some spark plugs for my '98 5.4L Expy when I came across a consumer affairs website which listed a number of individual's complaints regarding their spark plugs being blown out of their engine blocks. Has anyone heard of this? Seems really weird:

http://www.consumeraffairs.com/autom...ord_spark.html

It's pretty common on 5.4L. Do a search - you'll find a bunch of posts with horror stories and repair options.

99Expy 5.4: Yes, mine blew #3 this past summer. Cost $300 to have dealer fix with insert +plug, coil. Much better than the entire head $$$$$. Good luck.

I am now in the same boat...2000 Expy with a# 2 plug blown out of the block last night while holiday shopping. I found the Ford TSB 07-21-2 and it has information on the repair kit. I'm not sure if I can do this myself but I reallly cannot afford to have it repaired at this point.

BostonSound/DKDude: What was the mileage on both your vehicles when the plug failed and were the plugs ever replaced prior to that?

As a followup - Ford is advising cutomers to contact Rotunda via a tel # and order the repair kit. I checked out the repair process - it's not for the faint of heart. You're basically cutting into the engine block with a threaded insert (much like a screw) which the spark plug is then screwed into. It's highly recommended to pull the cylinder head cover off the engine as this will eliminate shavings falling into the cylinder chamber. If you've got the patience and skills, it's a lot cheaper to DIY rather than bringing it to a dealer or a mechanic (naturally). Here's hoping I never have this problem...

Evidently this problem has been fixed starting with the 03 models, yeah?

Spark plug issue
 

On my Expy the mileage is 86 K

I also have a 250 super duty ( 2003 ) with the 5.4 and I'm holding my breath and crossing my fingers !!

Thank you for all of the help !

FYI the "engine block" is not involved. Spark plugs make their home in the cylinder head.

Very True !! Sorry, My bad !

There are a number of individuals with '03 Expys who have had this problem. I don't know whether it's the same engine as in the F250 - anyone know?

***With respect to the "engine block" I mentioned above, I meant to say cylinder head - I'm not exactly the most mechanical person in the world and I have to read up on what the names of the specific components are. Sorry for any confusion.

Sorry for the confusion,

I have a 2000 Expy with the blown # 2 plug out of the head.

I also own a 2003 250 super duty with the 5.4 and I hope that the motor does not do the same thing.

Sorry to beat a dead horse, but I did some additional research on this and I've got some bad news. You can't buy the insert kit (#302-00001) from Rotunda (800-768-8632)- only the dealers can - and it costs around $1,000. It comes with 20 inserts and a measuring tool which can be used for the 3 different engines. The TSB is "TSB 07-21-2" link: http://fulltorque.com/pdf/Ford%20Tec...20Bulletin.pdf and it lists all of the affected models from 1997 to 2008. **Bostonsound - the F Super Duty affected is from 1998-2004, sorry. Sucks, I know. So you have only 2 options: take it to Ford to have the inserts put in or buy and install a new cylinder head yourself. Yikes.

You can buy the Time Sert kit. I beleive it is around $350.00 $400.00. I know of a few shops here in Omaha that do the repair for around $250.00 a hole. Still better than a new head. Some people on here have done all 8 holes.
Once fixed that hole should not be problem. Do a search on here for directions on changing the spark plugs. Torque is very important.

Awesome! The cheapest I've been able to find the kit (#5553) is $425 at eBay - it comes with 5 inserts. A heckuva lot cheaper, that's for sure. I found the instructions for a DIY repair: http://www.timesert.com/html/Triton-repair.pdf.