Mechanic says the #2 plug on pass side is blown and took threads with it and is in a bad location to get to. R&R engine and remove and replace with new head(s)? Or is there another way to effect the repair? If R&R engine is necessary, is there anything else I should have done while it's out? (I'm pretty sure I have a valve cover gasket leak-so I'd have that done) No previous mechanical work on it except for replacing a few coils. Van has 306K miles. I've had it 19 of it's 20 years - a member of the family.

 

From what I've read here IF the engine needs R&R it would be the perfect time to renew the exhaust manifold studs, using Ford's new and improved stainless steel parts.

I would seek a second opinion whether the existing head is indeed trashed, perhaps contact Blownsparkplugs.com checking if they have a recommended installer of their systems. Just from what little I know the #2 spark plug on a V10 in an F-Series hasn't been even nearly impossible to replace with a Timesert or similar part.

 

It is extremely rare to have to replace a head for these issues or even pull the engine.

Have him do an over the fender repair with a recommended insert (SnapOn/Calvan, TimeSert, or Lock-n-Stitch) kit. Avoid the impulse to use a Helicoil, Dorman, or similar cheap offering.

 

Agree, do a Time-Sert with the engine in the bay. No need to replace the head for this.

I also agree on the exhaust manifold bolts if you happened to already have it out for some other reason.