I bought a 2002 V10 2wd XLT 185K miles a couple months ago. I've been lurking on the forum absorbing advice as I work to bring the truck back to life. I bought it off the internet and thought I did a fairly thorough test drive and check of the vehicle. I checked to fluids before buying but the seller pulled a fast one and must've filled the transmission test tube with used but decent ATF. Didn't pay much for the vehicle and figured the known repairs would still make it a good deal for a tow vehicle. Transmission worked fine but when I took it in for a flush, the fluid was cooked and got the news it needed a torque converter and that failure was only a matter of time. I had the vehicle checked out by professionals (yes I know that in hindsight I should've done prior to purchase) to give it a thorough once over before spending additional money to do transmission work. Independent shop gave it an otherwise thumbs (including a report that the cylinder compression was all within 3-5% of each other. With a history of some misfire on cylinders 7 & 9 but nothing current. They didn't do a proper compression test but got info from computer).

So, I began the bringing the Ex back to near it's prime (tires, new steering gear install, muffler, hoses, reman transmission and TLC). I did the hoses, muffler, steering gear, and TLC myself. Today, I embarked on a spark plug and boot change. Read the excellent guides in the tech folder, watched some YouTube videos and did cylinder 1 to start just to see how it was done. I then did #5 (lots of cursing from Sammie's adjustable ladder platform tip), and #4. I figured I was in the home stretch of the passenger side with just #3 and #2 remaining.

Until something seemed odd when I tried to pull the boot of #3. It was stuck in the cylinder and I needed pliers to pull it out. Out came a shortie boot. I wasn't sure what was up but got concerned when my plug socket wouldn't fit on the plug. In hindsight, I should've probably stopped at that point and realized what was about to come out of the cylinder. A 17 mm socket brought out a Dorman 42025 blown plug repair. Not just the 3v plug but the whole insert. I didn't even have to apply a tremendous amount of pressure to get it out.

So now I'm wondering what to do since I have my son's field trip to northern Arizona coming up in two days where I'll be towing the travel trailer. I obviously don't have time to get a Calvan kit to do myself or to take it in to have a pro do it and cancellation is not an option.

I'm wondering what to do. I'm thinking my best option given the circumstances of having to use the vehicle in 2 days is to carefully reinsert the Dorman insert with red threadlocker, use a careful amount of torque on it (will have to research the installation instructions to see what the original specs for it was) and take it easy going up the mountains. Running on 9 cylinders with the injector unplugged doesn't seem realistic considering the towing requirement. Chunk of the money I was saving for a gear swap from 3.73 to 4.30 will be going to a proper fix ASAP.

Anyone have any advice on what they have done in this situation or what I should do to get through the weekend

Sorry my first post is to ask for help and advise but I'm feeling up a creek without a paddle right now.

 

That's what I'd do. Or, if you could find the Calvan kit, it doesn't look like it takes long to do. You could fix it tomorrow night.

 

Thanks for the quick response. I'll start looking for a kit locally since Amazon wouldn't get it here tomorrow.

Have all the tools necessary like air ratchet. One silver lining is that is is cylinder #3 and easy to get too unlike 4 and 5.

 

I hope you can find a kit locally. Good luck

 

Don't worry, I got 'em squared away.

Stewart

 

Not sure why my in depth first post wasn't showing up originally, but thanks for taking care of that.

Can't find any local source of Calvan or Time-Sert so I reinstalled the Dorman with extra thread locker, cranked it down tight, but not too tight so I wouldn't strip the aluminum threads with the steel insert and I'll be keeping my fingers crossed till Monday.

 

At least now the Dorman insert is tight, so you should be better off than before.

 

Yeah, I think you'll be fine. Good luck

 

Thank you for the reassurance! I bought a used Calvan 38900 kit off ebay last night. It will be here when I get back. Provided I return with a working engine, maybe I'll do up a report with photos of how the permanent fix proceeds.

 

Hope you were nearby with the Timesert (oversized) kit!

Good job Super-Stewart!

 

No, I got his duplicate thread squared away. He posted twice. See the quote in my post.

Stewart

 

Just an update. Made the 500 mile round trip without incident. The Calvan kit arrived so I'm gathering parts to complete the replacement. Ordered an inexpensive USB endoscope to examine the piston for clearance and removing all the metal chips as well as a bump starter switch to get the piston in the correct position.

As an aside, the Ex pulled the trailer up and down the mountains of Northern Arizona without a problem though I was down to about 40mph and 4000 rpm on the worst climb, a three mile 7% grade. Will definitely be looking into swapping out the rear 3.73 gearing. I monitored the transmission temperature from the OBD connection with the Fusion app. Never got scary hot, but definitely was getting up there. I added a TruCool auxillary cooler during the transmission replacement. Anyone know how the temperature reading from the computer compares to a dedicated sensor in the inspection port?

 

Congrats, glad your solution worked!
You seem to have the experience where I would like to ask for your advice. I had a plug blowout in an evening and needed to go to work the next morning. A buddy came to help but the only solution we could find was the infamous Dorman 42025. Which lasted all of 1/2 a block the next day. Like you I ordered a Cal Van kit.
The problem comes from part of the Dorman insert refuses to come out. Drilling has been very minimally successful. I am hoping that you will be willing to share with me how you got the insert out. We used red loctite also.
Thank you for your consideration!

 

I have no experience with the Dorman kit, but heat usually helps soften Loctite up enough to help removal.

 

The Dorman in mine was loose and came right out. That was how I knew what it was. I agree that unless the person used very high heat Loctite or JBweld (like you will use for the cal van insert) a blast of high heat should loosen whatever is holding the Dorman in. Best of luck. By the way, the cal van insert I put in worked fantastic and was easy to do.