spark plug blow out
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Junior User
Joined: Aug 2004
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From: Augusta, GA
spark plug blow out
I bought my 02 f150 4.6l a little over a week ago and have spent alot of time on this forum. I've been reading about spark plugs blowing out and it makes me a little nervous. Has this been a problem with the 02 4.6l? Is there anything else I should be concerned about? I just read a thing about tie rods. I had my 99 ranger for over 4 years and loved it, but after reading some of the problems about the f150 I'm almost regretting getting one. I love my new truck, but I don't want it to blow up on me. 
Freshman User
Joined: Jul 2004
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I understand what you are saying. I own a 93 Ranger and other then ball joints and a starter motor, thats all I replaced.( I dont count brakes or battery because these things are just a matter of time.) My 2000 F 150 is something else though. It blows blue smoke on start up that the dealer cant figure out. I too worry about spark plug blow out ( when I read about this ,I wont even punch my truck anymore) These COP i dont understand, I cant even see my spark plugs and now tie rods. If I knew all this back in 2000 I would of bought something else. Sorry Ford. PS. I miss my 5.0 Mustang. Now thats a motor.
New User
Joined: Jul 2004
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Look at these numbers. Ford has sold a million trucks with 5.4 L triton. I personally know one person that had this problem after he had his spark plugs replaced at about 50,000 miles... #4 blew out at 107,000. He also modified his truck at least a little. He fixed it his self for about $130.00. The company that makes the insert says that they have sold about 2,000 kits to ford owners. Those include the good old boys that modify their trucks to make them run fast and play hard. The average person that leaves their repair work (i.e. changing the spark plugs) to someone that is qualified and is not the kind of person that thinks that the gas pedal has only two positions (i.e. off and on) will probably never have any problems and basically the engine is solid. Changing the spark plugs on this engine is not for the novice. There are people on this forum that have over 250,000 miles on their truck. Does this sound like a piece of junk? So remember that when you think about modification (i.e. changing the codes in the chip)...if you play, sometime you have to pay!
Freshman User
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Hello 7 lug head. Would you know if any of the 4.6 engines spit out their plugs. The service manager at the dealer I go to (SVT truck center) told me so far he has 6 or 7 that did this, but didnt specify which motors. I should have asked him but this guy is so busy he wont stay still long enough.
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plug blow out
7 Lug head said "He fixed it his self for about $130.00. The company that makes the insert says that they have sold about 2,000 kits to ford owners."
what is the name of the company??? this problem happened to me recently and am in need of repair info. I have a 4.6L V8 2001 with 50k
any help would be appreciated.
what is the name of the company??? this problem happened to me recently and am in need of repair info. I have a 4.6L V8 2001 with 50k
any help would be appreciated.
5th Wheeling
Joined: Feb 2004
Posts: 25
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spark plug repair kit
I have been reading in forums that Ford doesn't repair blown out spark plug threads. I recently suscribed to the online workshop manual at http://www.motorcraftservice.com.
There is a section in there that describes how to repair the threads using a "Sav-a-Thread Master Kit" -Ford part number 107-R0921 or equivalent.
The head must be removed, of course, to keep aluminum chips out of the cylinder.
There is a section in there that describes how to repair the threads using a "Sav-a-Thread Master Kit" -Ford part number 107-R0921 or equivalent.
The head must be removed, of course, to keep aluminum chips out of the cylinder.
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Freshman User
Joined: Mar 2002
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From: In a house, mostly
Mine #3 blew out at 104K, original plugs, I baby my truck. In my case I can't excuse Ford for this obvious design flaw.
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Joined: Mar 2002
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From: In a house, mostly
Did your truck actually eject a plug yet or is it just running rough ?
All the post that I have read from others much more knowledgable than I seem to indicate that the root cause for plug ejection is that there are simply not enough threads to keep the plug in place long term. As a mechanical engineer, I'm of the opinion that there are few design problems simpler than keeping a threaded thingy in a threaded hole, this is a tragic design flaw in an otherwise fairly sturdy engine.
One Ford dealer tried to tell me that the root cause of plug ejection was detonation, where pressures rose to 3 - 10x above normal. I suppose next they will tell us that the plugs blow out to prevent even more serious rod or crank shaft damage, sort of like blowing a fuse.
One seemingly honest service manager actually did fess up to it being a design flaw, this fellow also mentioned that Ford will actually compensate owners that are under 75K miles.
All the post that I have read from others much more knowledgable than I seem to indicate that the root cause for plug ejection is that there are simply not enough threads to keep the plug in place long term. As a mechanical engineer, I'm of the opinion that there are few design problems simpler than keeping a threaded thingy in a threaded hole, this is a tragic design flaw in an otherwise fairly sturdy engine.
One Ford dealer tried to tell me that the root cause of plug ejection was detonation, where pressures rose to 3 - 10x above normal. I suppose next they will tell us that the plugs blow out to prevent even more serious rod or crank shaft damage, sort of like blowing a fuse.
One seemingly honest service manager actually did fess up to it being a design flaw, this fellow also mentioned that Ford will actually compensate owners that are under 75K miles.
Lead Driver
Joined: Jul 2003
Posts: 7,404
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From: Wheatland, Mo
Another issue to consider is that many of the trucks that "popped" their plugs were due to over tightening of the plugs when last changed. This will break what little threads there are and cause the plug to get airborne. If you insist on changing them yourself, be sure to follow factory torque specs TO THE LETTER. (Or number in this case).
Senior User
Joined: Nov 2003
Posts: 116
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From: Naperville, IL
Is it true that there was a design change on the '03 models to prevent this problem?
Also, you need to keep in mind that even though you hear about a bunch of those problems on this board, there are millions that don't have the issue.
Also, you need to keep in mind that even though you hear about a bunch of those problems on this board, there are millions that don't have the issue.
Posting Guru
Joined: Jan 2003
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From: Magrath
You should be fine. When they had the deal on the news here in MN the other day, they stated that the majority of the problems happened on the 5.4L.
I have yet to meet anyone that has had a plug blow out, and a few of my buddies have over 150000miles on thier trucks.
I have yet to meet anyone that has had a plug blow out, and a few of my buddies have over 150000miles on thier trucks.
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