Go read this page: ++ TIME-SERT KITS ++ helicoil save-a-thread failure Spark plug blow out spark plug blown out

The Helicoil Sav-A-Thread and the parts stores look-a-likes do not bore out the hole to a larger diameter, they just run a thread chaser down the existing plug threads before putting in their insert, then they use a smaller diameter spark plug inside the insert. Unless the head suffered severe damage when the plug came out (yours obviously didn't since the insert was unscrewed, not blown out), the 5553 is the correct Timesert tool set for the job.

In the unlikely event that a last chance, triple-oversized repair insert is needed, you have to use that tool kit (5600) first, then use the 5553 kit to install a 51459 insert into the larger one.

 

Edit: I see you edited your post with the exact information I was asking haha.

 

It sure looks like the HeliCoil inserts I have seen advertised.
The type you describe sounds like a HeliCoil thread repair, which is more like a spring that is threaded down into what is left of existing threads vs the insert which I would describe as more of a bushing with threads inside and out. And I agree, this is definitely not suited for this repair:



^ spring type HeliCoil thread repair



This is a Time-Sert insert.
Notice the collar at the top to positively locate it in the correct position in the spark plug hole with no possibility of threading it in too far. This is what I used to repair my engine and if I had to do it over again I would not hesitate to pay full price for the Time-Sert Triton spark plug thread repair kit.



Time-Sert brand Triton insert for spark plug hole thread repair





(below) This is what a HeliCoil insert looks like pre-installation with the knurled top edge that requires hammering into the head to keep it in place. The Sav-A-Thread kit is made by HeliCoil, notice the branding stamped into the tools in this screen grab from the Amazon sales page:



Another big issue I have with this type of insert is that they have no collar at the top to stop it from being threaded in too far which could leave your spark plug too far in causing interference with the piston or valves. Or in the case of OP C Milk, it looks like his wasn't threaded in far enough and it was hammered and split without being fully seated into the hole.
The Time-Sert insert has a collar at the top so you can't thread it in too far, and you know for certain when it is threaded in just right. It is held in place by expanding the threads on the insert.
Read the info on the Time-Sert site.



Sav-A-Thread kit costs about $30 on Amazon, about $60 retail at Advance, and it will cost you a whole lot more than that if you ruin the head hammering this thing in to install it.

 

I did find those same images after projectSHO89 posted the words Heli-coil thread saver.

So I will end up taking the two plugs out this weekend to measure the OD. Hopefully it should be .660 or slightly under.

 

Best post ever. Reps sent!

 

I've had real good luck with the Dorman thread repair kit. It's much cheaper and easier than a helicoil kit. Dorman 42025 Cyl Head Repair Kit 1999 2005 Ford 5 4 L | eBay

 

You might as well play Russian roulette with four bullets in the revolver. It's worse than the Sav-A-Thread.

 

LOL ok buddy I guess you haven't had good luck with them. Maybe it's the person turning the wrench that has more to do with it.

 

Uh, no....

Half of the rentals I've done were to guys who had either Dorman or Helicoils that failed.

 

Well since you're ruining the head with these kits I would put some JB weld on the dorman kit and I guarantee it isn't coming out. It's all about how many miles are on the truck, your budget and how long you plan on keeping it. I was helping a neighbor do a spark plug change on his 5.4 F150 and someone had epoxy or JB welded the entire spark plug in the number 5 plug hole. He has over 270k miles on his truck so I told him just leave it alone and that will probably be the last plug that hole ever gets.

 

No reason to start fighting amongst friends. Helicoils are not meant for spark plugs, hence the tang at the end that would interfere with spark. Different inserts work differently for each situation, meaning that if you haven't blown a plug, you may not need the more expensive option to repair it. The objective here is to help the OP get the truck back on the road. Lets keep our opinions to ourselves, and offer verified advise to correct the issue.

 

I can verify the TimeSert works. There is plenty of verification that many other repairs work temporarily. I used TimeSerts on a 4.6. I used it because the reviews said it worked permanently. Not so much for the others. If the OP tries to repair those plugs with something similar it is going to be a temporary fix. There is too much evidence out there to make anyone leery of the HeliCoil style or SaveAThread. My wife's expedition had a TimeSert installed at 40K miles and it now has 230K and 3 plug changes since with no backing out or blowing out of the TimeSert.


The only other kit I can recommend besides TimeSert is the LockNStitch kit. The fleet tech for a landscape company I worked for used one of these and I can say it appears right on par with the TimeSert. This company had 14 SDs and all had 5.4s.

 

I considered Lock-N-Stitch but went with the Time-Sert because Lock-N-Stitch inserts are aluminum and Time-Sert inserts are high carbon steel.

 

Anyone in the Kansas City area have experience fixing this type of problem? I just pulled the rear plug on the passenger side and it came out like the photo above. I can't find a replacement locally so I had no choice but to put it back in. I think I want to repair it with the Time-sert but I can't swing the entire kit right now. Maybe someone could rent me theirs?

 

I timeserted all on my V10. Bought the kit on eBay, 10 inserts and resold it on eBay for a little less than I paid. So you won't really be out the $400 fo the kit.