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I am currently moving myself and family from Ft. Lewis, WA to Ft. Hood, TX. We have made it to Cheyenne, WY and our moving truck started having issues. So we sit at a truck stop having them look at it all afternoon. As we are leaving I apply pressure on the accelerator pedal and hear a loud POP and a massive exhaust leak sound. I pull into a parking lot down the street and open the hood. What do I find? A COP laying sideways on the intake manifold with no spark plug in sight!! I looked into the hole and don't see any damage, but can't see if there are any threads left either.
I wouldn't let them helicoil it. Insist on an insert. It's the only proper way to fix the problem, short of replacing the head.
Tell the dealership to refer to the Ford TSB regarding spark plug ejection. Their own TSB states the proper way to fix the problem is with a threaded insert.
Stewart; I think I used the wrong term. I did ask them how it was to be repaired and he told me they were going to use an insert (kinda like a helicoil he said). After he said that I asked if this was in accordance with the ford directive and he claimed yes it is. Hopefully this ends up well for me and the truck.