1999 E-350 Super Duty 15 Passenger Van
5.4L V-8
~170000 miles
Purchased for $2200 about 3.5 years ago

Here's a sob story for you.
I was on the road with my band, when a spark plug blew out of the engine. Of course it was at 6pm on a Saturday. This was day three of a 20 day trip around the U.S. So we got towed to the "guy" that the tow truck driver knew. He was able to helicoil the cylinder, and get us back on the road. It was running a little rough, but we were on our way. So over 1000 miles later, the same spark plug blew again. This time we were able to take it to a more reputable shop. Again, they put a helicoil in, and we were on our way. Van was running way better, and we thought the troubles were behind us. So fast forward two weeks, and over 3500 miles, we were heading home, guess what happens again. Yup, same spark plug blew again (right after we put $100 in the gas tank of course). We are still about 1000 miles from home, and the shop we took it to said they put a helicoil in, and it blew out as soon as they started the engine. They quoted me $3500 to replace the cylinder head. We needed to get home, back to our jobs and significant others, so we made the hard decision to leave the van, rent a couple of cars, and drive home. I had succumbed to the fact that I would have to try to sell it for whatever I could get, and start over with a new vehicle. The cost of transporting the van 1000 miles, and having to spent a few grand on repairs just didn't seem worth it.
Now a friend of mine who is a mechanic offered work on the van for next to nothing. Here's my questions. What parts will I need, and how many hours of work is required to replace the cylinder head? Is there any other possible fixes for the problem? Is the other side likely to have the same problem soon? Any other thoughts?
How long do the transmissions tend to last on these vans? My previous van, a GMC (I know, I know), had the transmission overhauled, and threw a rod through the engine a few weeks later. I don't want this to become a money pit. I'm really torn whether its worth shipping it back. Any advice or thoughts would be greatly appreciated.
-Brian

 

Did you confirm that it's the same cylinder blowing out spark plugs?

Check local listings for a suitable replacement so you have an idea of the upper cost limit of repairing the van that broke down on you.

Sixto
'93 E150 Chateau 5.8 185K miles

 

yes, its most definitely the same cylinder each time.

 

Ive been doing more research. Anyone have any success or failure with either Time-sert or CalVan kits? Seems like one of these might be a good fix, but it seems like all the positive comments have been made after a couple hundred miles have been put on after the repair. I'm interested to find out about how they hold up 10, 20, 30 thousand miles and on.

 

Heads are disposable, when they act up, replace em with new!

 

If they are aluminum heads it might be because the previous repair using thread inserts was the aluminum thread inserts. Go with the steel inserts if you fix the hole. Ford's thread fix kit is aluminum inserts which is setting the hole up to do the same thing again. Commonly on aluminum heads the rearward portion of the engine takes the most heat which with aluminum weakens the metal. Weaker in thin threads means flying spark plugs. The steel inserts are doubly better with aluminum heads since you dont get the gauling where steel and aluminum bond like welding the two together making it so removing a spark plug rips the threads out.

 

Now you have me thinking - 1998 Ford E350 CHURCH VAN 12 PASSENGER

We don't need another van but natural gas would be nice.

Sixto
'93 E150 Chateau 5.8 185K miles

 

The problem with NGL is getting fuel on the road. Good for local use where you know where you can get fueled but not on a cross country trip.

 

You will need to use a Calvan insert because of the Heli Coil install (mahes the hole too big for time sert). I just used the napa kit which works, but if you can afford the calvan I would do that. I wonder if either of these shops changed your COP? they usually break when a plug blows and though they (may) be able to bolt in again, there could be a grounding issue... Good luck

 

snap-on makes a kit to fix this while the head is still on the engine. Takes about an hr to do. Kit cost $400 and has enough inserts to do 4 or 6 plug holes( don't remember #) I did one years ago and then put another 300,000 miles on motor. $3500 to change a head is robbery, $1500 max for labor plus head cost.
JKaz