I have a 1999 Ford F250 4x4 superduty with the 6.8 Liter V-10 engine. The common spark plug issue with the it blowing out of the hole happened to me the other day. So see online its no big deal, just order the Dorman 42025 spark plug repair kit for 40.00 bucks and install it. Well I go to install it and the tap that they give me with it I see it is obviously smaller than the spark plug that was in my truck. So the tap wont thread in since the spark plug hole is bigger in my truck than the tap they give you with the kit, anyone have this problem or am I doing something wrong with the kit?

 

The Dorman 42025 appears to be the correct kit.

Is it possible that this cylinder has been repaired before?

 

I just removed a dorman from mine and used a TimeSert. I think they make a BigSert kit if the hole is too big. Worth the money for the peace of mind. Haven't heard good things about the dorman repair.

 

Are you sure the "tap" isn't the insert tool for the helicoil?