Cop Problem Again
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Senior User
Joined: Feb 2004
Posts: 126
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From: CANADA
Cop Problem Again
This problem never ends! When ever it rains and i'm running logging roads with the 5.4l for my work, we loose a coil.The rear passenger coil is a bi PITA to get at.Ford needs to do something about it.14 coils in 140,000 KM.I know this gets beat to death but is anyone else experiencing these quantity of problems? 
Post Fiend
Joined: Jun 2003
Posts: 5,643
Likes: 8
From: NE Texas
I don't know if I personally have addressed this problem here, but here's my opinion:
There has to be a problem other than the coils themselves. There could be a seating problem with that rubber boot on the head (plug cavity). Do you coat it good with dielectric grease before you install it? Have you checked for breaks, tears, cracks, and/or "spark marks" (those small burned areas)? What about the electrical connectors? Are they sealed?
There are many ifs, ands, and buts, but there has to be something about your engine exclusively, or your setup.
It is a strange situation, though.
I haven’t experienced that sort of thing, myself.
There has to be a problem other than the coils themselves. There could be a seating problem with that rubber boot on the head (plug cavity). Do you coat it good with dielectric grease before you install it? Have you checked for breaks, tears, cracks, and/or "spark marks" (those small burned areas)? What about the electrical connectors? Are they sealed?
There are many ifs, ands, and buts, but there has to be something about your engine exclusively, or your setup.
It is a strange situation, though.
I haven’t experienced that sort of thing, myself.
Thread Starter
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Senior User
Joined: Feb 2004
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From: CANADA
My dealer mechanic says ,that it's all the vibration & dirt the motor is getting is the trouble.He said that it's a poor design for a guy like me.Makes the truck run rough as hell till it gets home.I worry about loosing a cylinder.
Post Fiend
Joined: Jun 2003
Posts: 5,643
Likes: 8
From: NE Texas
You must really get down and dirty out there, Hotshoe.
But, there's got to be another explanation. My youngest son puts his 5.4 through the worst gunk I’ve ever seen. He’s never had that kind of trouble. You can’t even see the coils sometimes.
Maybe someone that’s experienced this will come along with a better explanation, but right now I’ve got to stick with the boots and/or connectors not sealing as being the problem.
But, there's got to be another explanation. My youngest son puts his 5.4 through the worst gunk I’ve ever seen. He’s never had that kind of trouble. You can’t even see the coils sometimes.
Maybe someone that’s experienced this will come along with a better explanation, but right now I’ve got to stick with the boots and/or connectors not sealing as being the problem.
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Senior User
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From: CANADA
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Post Fiend
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Lead Driver
Joined: May 2003
Posts: 9,303
Likes: 48
From: Lyndonville, Vermont
I used those wheel well protectors to keep the junk out they work real well...
https://www.ford-trucks.com/forums/s...52B%25252Bwell
https://www.ford-trucks.com/forums/s...52B%25252Bwell
I hope ya know I was kidding...
Posting Guru
Joined: Oct 2003
Posts: 1,332
Likes: 4
From: Baltimore
Sounds like water migrating into the spark plug cavity. I've had it happen when cleaning the engine. Water seems to collect in the rear hole. You might try putting a small bead of silicon sealant around the top of the boot where it meets the flat of the cylinder head to see if it helps.
Post Fiend
Joined: Jun 2003
Posts: 5,643
Likes: 8
From: NE Texas
I take from your post, I got her back, that you had this done. Did you get a chance to observe the replacement procedure? I was thinking: There is a small brass bushing on the COP flange that stops the attachment screw from distorting the seal when tightened. Maybe there's a burr or deformity in that area that prohibits the rubber from sealing around the plug cavity?
In my way of thinking, there has to be something allowing water/mud to contaminate the coil connectors - either at the spark plug contact or at the outer electronics area.
In my way of thinking, there has to be something allowing water/mud to contaminate the coil connectors - either at the spark plug contact or at the outer electronics area.
Thread Starter
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Senior User
Joined: Feb 2004
Posts: 126
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From: CANADA
No problems today.
Anyone have a pic of the wheelwell protector installed?I ordered a pair.If it works i'll be putting them on the rest of the Super Duties.The F150 already had some.I never noticed them before.
Anyone have a pic of the wheelwell protector installed?I ordered a pair.If it works i'll be putting them on the rest of the Super Duties.The F150 already had some.I never noticed them before.