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From what I can tell there are similarities between the two. Setting aside the plug issue, can it be said that the 5.4L is more problematic? If you search 5.4L issues you have lots of youtube videos...(timing chain/tensioners, oil pump,VCT but nothing for the 6.2L
Could it be that there are just allot more 5.4's with allot more miles and they learned a bit from the 5.4 and made the 6.2 better?
My 04 5.4 has 168k on it at the moment, all original except oil changes, air filters, spark plugs and cop boots ONLY. Never once has left me stranded, do I wish it was more powerful YES but has it hauled and towed whatever i threw at her YES SHE HAS
The 5.4 2v is actually a really good engine minus one issue that not everyone has, which is spark plugs blowing out. I have an 02 5.4 with over 220k with nothing done to the engine except a knock sensor, intake and exhaust manifolds. It has been an awesome truck, albeit underpowered.
I had an 06 3v and had the phasers take out the engine. It did have more power and i loved the way i6 drove, but I won't have another 3v.
now the 6.2 literally does not have a single common failure point like both versions of the 5.4 have. I absolutely love my 6.2. It seems to have twice the amount of power that the other two have. Tows better, daily driving is better, its way faster, and doesn't have any common problems
they added more threads in the heads to stop them from shooting out, but the 05 and up had a problem where they would break off inside the head when changing them. Not a huge deal if you got the special tool to remove them
The 5.4 is underpowered in the super duty however a properly maintained 2 valve will go 300k+ fairly easily. The 6.2 has more power and the reliability is just as good if not better. I have owned both and 6.2 wins.
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Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.