Common issues with the 5.4?
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New User
Joined: Aug 2012
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From: Homeland, CA
Common issues with the 5.4?
Hi everyone! Been a while since I've been on here but I thought I'd come back asking this question: what are the common issues with the 5.4? The reason I ask is because I have a 2003 F250 with the 5.4. In the last couple years I had 2 spark plug holes blow out, and now this past week the water ports on the intake broke around the gasket, causing a massive leak. From what I've read this are common issues with the 5.4. So my question really is what are the common issues that I should probably be concerned about in the future? My engine has 298,000 miles on it. Thanks in advance.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
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From: Thousand Oaks, CA
I've changed the Exped plugs every 50k and torque to 25 ft/lbs.
The plug that blew on the 6.8L was an OEM plug with 108k and was probably torqued to 15 ft/lbs at the factory.
Changing the plugs at 50k and torque properly should eliminate your issues, or at least retorque at 50k.
The plugs can work loose after a lot of miles, even in the 8 thread heads, which just take longer to blow out.
Do not use a helicoil for the repair, a Timesert insert in ours works great.
Timesert even carries a helicoil repair insert.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
Likes: 88
From: Thousand Oaks, CA
.... this past week the water ports on the intake broke around the gasket, causing a massive leak. From what I've read this are common issues with the 5.4. So my question really is what are the common issues that I should probably be concerned about in the future? My engine has 298,000 miles on it. Thanks in advance.
Ours has 170k and has been trouble free, engine wise, except for now it needs timing chain tensioners.
There's a loud clicking coming from the front at startup, which goes sway after a couple of minutes.
The chains are probably stretched, too, and I'm going to change the oil pump, water pump and radiator while in there.
The radiator in tank trans cooler is clogged and I figure the plastic tanks are getting there just from age.
Not surprised about the plastic intake, there is an improved aftermarket replacement available, I'm impressed it lasted that long.
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New User
Joined: Aug 2012
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From: Homeland, CA
Almost forgot I had 1 lifter (hydraulic lash adjuster) go bad, but yeah, those are the only major issues I've had so far. For the intake I got the Dorman model. It seemed like a better design for the most part, except that it takes self-tapping screws to hold almost everything in place.
Senior User
Joined: May 2018
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On the 2001 I've blown one spark plug, developed a leak in the passenger side exhaust manifold, replaced the alternator, and replaced the radiator overflow tank because of a leak. Pretty good for 190,000 miles with regular maintenance.
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coolfeet
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