Spark plug popped out!!!
Spark plug popped out!!!
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Freshman User
Joined: Apr 2003
Posts: 28
Likes: 0
From: Bucks County, Pa
Spark plug popped out!!!
I have a 1997 Expedition/5.4l and the #2 cylinder spark plug popped out and broke the coil pack associated with it. I contacted a Ford dealership and they said that there has been a problem with that model engine doing that! They informed me that I would either have to replace the head or replace the engine!!! Both options will be a lot of money with the associated labor charge. The engine is out of warranty and I seem out of luck. A service technician at the dealership also informed me that the plug hole could not be sleeved because they could not get to it. Anyone have the same problem?
Logistics Pro
Joined: Oct 2000
Posts: 3,960
Likes: 5
From: All over Texas
Spark plug popped out!!!
No this has not happened to me, but has recently happened to 1999XLT.
This has been a major topic of discussion lately. Try a "search" of the Expedition and F150 forums as well as the 5.4L engine forum for very detailed information. Much more discussion can be found on the engine forum.
This has been a major topic of discussion lately. Try a "search" of the Expedition and F150 forums as well as the 5.4L engine forum for very detailed information. Much more discussion can be found on the engine forum.
Hotshot
Joined: Aug 2002
Posts: 12,679
Likes: 15
From: BC, Canada
Spark plug popped out!!!
Hi cantman and welcome to FTE 
Ford's official position on this is that the head has to be replaced but I've seen Heli-coils put in the holes and they worked ok.
It takes a good mechanic or a machine shop to do it without causing any more damage.
Number 2 cylinder is one of the easier ones to get at but it's still not much fun.
Ford's official position on this is that the head has to be replaced but I've seen Heli-coils put in the holes and they worked ok.
It takes a good mechanic or a machine shop to do it without causing any more damage.
Number 2 cylinder is one of the easier ones to get at but it's still not much fun.
Hotshot
Joined: Aug 2002
Posts: 12,679
Likes: 15
From: BC, Canada
Spark plug popped out!!!
Hi cantman and welcome to FTE
Ford's position on this is that the head has to be replaced but I've seen Heli-coils put in the holes and they worked ok.
It takes a good mechanic or a machine shop to do it without causing any more damage.
Number 2 cylinder is one of the easier ones to get at but it's still not much fun.
Ford's position on this is that the head has to be replaced but I've seen Heli-coils put in the holes and they worked ok.
It takes a good mechanic or a machine shop to do it without causing any more damage.
Number 2 cylinder is one of the easier ones to get at but it's still not much fun.
Elder User
Joined: Jul 2002
Posts: 719
Likes: 1
From: Long Island USA
Spark plug popped out!!!
Welcome CANTMAN. Let me just say REPLACE THE HEAD. I am a recent victim of this but mine was the dam #4. Do a search of my recent posts and you will see what you are in for. Good luck bro.
OH yeah and see if you could borrow a friend or family members car for a few weeks.
GOOD LUCK IT IS A................ P.I.T.A.
OH yeah and see if you could borrow a friend or family members car for a few weeks.
GOOD LUCK IT IS A................ P.I.T.A.
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Freshman User
Joined: Apr 2003
Posts: 28
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From: Bucks County, Pa
Spark plug popped out!!!
I think I cleared up my spark plug problem by installing another one and torqueing it to Ford specs. My "Check Engine" light came on after the plug popped out. How do I get it to reset itself?
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Elder User
Joined: Jul 2002
Posts: 719
Likes: 1
From: Long Island USA
Spark plug popped out!!!
Cantman, I had the plug pop out. I torqued it back down to spec and all was well. It worked for about 3 months and Bam. it popped out again. I was originally able to reseat the plug but apparently the damage was done the first time. Some of the threads were gone. On these heads there are not too many threads to begin with and once a few go it is only a matter of time before you lose the rest. I would keep a CLOSE eye on it and not plan any long trips anytime soon. I know I sound like a doomsday sayer but trust me this is from experience.
As far as the light goes just disconnect your negative battery terminal for a few minutes and that will erase the code.
Good Luck.
As far as the light goes just disconnect your negative battery terminal for a few minutes and that will erase the code.
Good Luck.
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New User
Joined: Apr 2003
Posts: 3
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Spark plug popped out!!!
My friend had that happen to him as well. The dealer installed a heli coil and new plug. It is worth trying before installing a new head. The practice has been done for years. I had it done on a Probe that I owned years back. The fix lasted the life of the car. If you ever have to take that plug back out...just be very sure the engine is ice cold. If not the heli coil has a better chance of coming out with the plug. Best thing to do is make sure you put a quality plug in and leave it in.
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