Expedition Spark Plug Ejection

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Jan 8, 2004 | 11:32 AM

Paul EXP

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Joined: Jan 2004

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Expedition Spark Plug Ejection

Hi all, new to the site. I'm doing some research on what I thought was a unique problem, but I'd like to see as it may not be as unusual as I thought. It seems one of the spark plugs blew clean out of the head last week. Preliminary research indicates that this is a design defect that is not all that uncommon (and not being acknowledged by Ford). The heads are aluminum and the threads aren't deep enough and over time they strip and eject a plug. The dealership insists this isn't that common but a quick check on consumeraffairs.com revealed 15 cases listed on just that site. I've also seen several references on this site on an old thread.
I'd like to find out how common this is and if anyone has had any luck getting their warrenty company to cover it. I'm currently fighting with EZ Care but I'm afraid I'm up against a precedent setting situation so they are going to fight it tooth and nail.
Also. has anyone had anyluck with heli-coils or similar re-tapping procedures?

Thanks for all responses