What year was the sparkplug ejection fixed?
Senior User
Joined: Jan 2008
Posts: 420
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From: New Hampshire
I only heard of the 5.4s having this problem for the most part. It was mainly with the plug/s that was the two piece deal. If it was an issue with a certain year, I dont know for my 98 4.6 has never had an issue and she has around 182k.
Fleet Owner
Joined: Aug 2010
Posts: 21,255
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From: Reynoldsburg, Ohio
If I'm in error here someone hopefully will correct me...............
In about '03 or '04 all modular heads had the plug holes modified to have approx eight threads per hole as opposed to the earlier verions with only four.
Honestly it seems this issue wasn't necessarily from a bad design but more from poor maintenance along with incorrect techniques used during plug changes. Having now owned two E250's with "early" modular motors there have been no issues. Following the recommended plug changing suggestions appears to solve or greatly reduce this problem.
In about '03 or '04 all modular heads had the plug holes modified to have approx eight threads per hole as opposed to the earlier verions with only four.
Honestly it seems this issue wasn't necessarily from a bad design but more from poor maintenance along with incorrect techniques used during plug changes. Having now owned two E250's with "early" modular motors there have been no issues. Following the recommended plug changing suggestions appears to solve or greatly reduce this problem.
Moderator
Joined: Dec 2001
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From: Louisville,Ky.
The only 2V heads with 8 threads are on engines from the mid 2003 model and up. All early 2003 back have 4 threads in the head.
Sorry Hodges710, you have 4 thread heads.
Yes, the main issue is from either loose plugs or from them being over torqued and pulling the threads loose in the heads.
Sorry Hodges710, you have 4 thread heads.
Yes, the main issue is from either loose plugs or from them being over torqued and pulling the threads loose in the heads.
Senior User
Joined: Jan 2008
Posts: 420
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From: New Hampshire
The only 2V heads with 8 threads are on engines from the mid 2003 model and up. All early 2003 back have 4 threads in the head.
Sorry Hodges710, you have 4 thread heads.
Yes, the main issue is from either loose plugs or from them being over torqued and pulling the threads loose in the heads.
Sorry Hodges710, you have 4 thread heads.
Yes, the main issue is from either loose plugs or from them being over torqued and pulling the threads loose in the heads.
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Postmaster
Joined: Nov 2006
Posts: 4,517
Likes: 3
From: SE Wyoming
You don't have a stock '98 engine with 8 threads.
As for curing it, there have been a few on the forums that allegedly have still spit a plug with 8, too many variables to prove it wasn't operator error on an install or they really had an early '03 with 4.
The 2 piece issue is for 3V's from '04- mid '08MY and they break in half because the plug seizes in the head. I suppose your 8 thread '98 also has 2 piece 3V plugs too though.
As for curing it, there have been a few on the forums that allegedly have still spit a plug with 8, too many variables to prove it wasn't operator error on an install or they really had an early '03 with 4.
The 2 piece issue is for 3V's from '04- mid '08MY and they break in half because the plug seizes in the head. I suppose your 8 thread '98 also has 2 piece 3V plugs too though.
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Senior User
Joined: Jan 2008
Posts: 420
Likes: 0
From: New Hampshire
You don't have a stock '98 engine with 8 threads.
As for curing it, there have been a few on the forums that allegedly have still spit a plug with 8, too many variables to prove it wasn't operator error on an install or they really had an early '03 with 4.
The 2 piece issue is for 3V's from '04- mid '08MY and they break in half because the plug seizes in the head. I suppose your 8 thread '98 also has 2 piece 3V plugs too though.
As for curing it, there have been a few on the forums that allegedly have still spit a plug with 8, too many variables to prove it wasn't operator error on an install or they really had an early '03 with 4.
The 2 piece issue is for 3V's from '04- mid '08MY and they break in half because the plug seizes in the head. I suppose your 8 thread '98 also has 2 piece 3V plugs too though.
New User
Joined: Jan 2016
Posts: 1
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Must be just lucky
2010 F-150 5.4L
One of mine blew this morning. TSB 07-21-2 states that F-150's were only affected from 1997-2003 but it didn't help me. Just passed 99k miles and pretty sure my 5 year warranty just expired a few months ago. What a great day ...
One of mine blew this morning. TSB 07-21-2 states that F-150's were only affected from 1997-2003 but it didn't help me. Just passed 99k miles and pretty sure my 5 year warranty just expired a few months ago. What a great day ...
Junior User
Joined: Jul 2015
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I read somewhere that the issue was fixed by November 2002.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
Likes: 88
From: Thousand Oaks, CA
Not changing the plugs for 100k+ seems to be a big part of the issue.
The plugs can work loose and eventually blow one out.
My 2002 6.8L has the PI heads with 7 or 8 threads and it blew one out at 108k.
I changed plugs/boots on our 2003 5.4L at 100k and am now changing them again at 150k with no problems so far.
There are at least 5 or 6 other cases I have read about that blew out plugs with 100k+ miles on them.
At the very least check the torque at 40k or so.
I'll be changing plugs/boots every 50k and checking the torque (14ft/lbs) at 10k.
The plugs can work loose and eventually blow one out.
My 2002 6.8L has the PI heads with 7 or 8 threads and it blew one out at 108k.
I changed plugs/boots on our 2003 5.4L at 100k and am now changing them again at 150k with no problems so far.
There are at least 5 or 6 other cases I have read about that blew out plugs with 100k+ miles on them.
At the very least check the torque at 40k or so.
I'll be changing plugs/boots every 50k and checking the torque (14ft/lbs) at 10k.
Fleet Owner
Joined: Aug 2010
Posts: 21,255
Likes: 1,657
From: Reynoldsburg, Ohio
Proper installation and proper torque does seem to have a huge influence over this issue so careful attention is paid there. I use nothing but Motorcraft plugs, a dab of nickel-based anti-seize on the treads as well as torquing them in at 22-23 ft/lbs. In just about 200K miles with two different E-Series 5.4 motors I've yet to have any issues at all with loose or blown out plugs.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
Likes: 88
From: Thousand Oaks, CA
I thought the same, but when I changed the plugs on the 5.4L and 6.8L at just over 100k they were running great and the plugs looked fine. I'm still going to change them at 50k. The 6.8L #3 plug was the one that blew out. I checked the torque, 14ft/lbs, on the 6.8L plugs before I removed them and all the bank 1 plugs turned a bit before the wrench clicked. Bank 2 was tight.
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