98 5.4 - Insert, Replace Head, or Engine
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Freshman User
Joined: Mar 2002
Posts: 33
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From: In a house, mostly
98 5.4 - Insert, Replace Head, or Engine
Now that it's official, #3 plug launched and took the thread with it. I'm faced with some choices:
1. 4900 installation of a rebuilt engine (3 year \ 36,000 mile warranty)
2. 2500 passenger side head replacement (1 year \ 12,000 mile warranty)
3. 400 & a few busted knuckles for the insert, which hopefully can be done without removing the head.
What I'm wondering is if I'm ultimately just going to pop another one and be back to square one.
I would almost go for the head replacement if I could be sure that the replacement head isn't as defective as the one there putting on.
Is it mostly the right side that is prone to this defect, if not, maybe I should just clinch my teeth and go for the factory rebuilt engine.
Would I stand a chance at doing the insert on my own, I'm handier than most, can do breaks and other light repairs, but have not tackled anything like removing a cylinder head.
Any help would be greatly appreciated.
Oh and if there are any other victims of this problem, according to the (4) ford dealers that I spoke to today and the customer realations center, I'm the first one to ever report this problem........ha.
Jeff
1. 4900 installation of a rebuilt engine (3 year \ 36,000 mile warranty)
2. 2500 passenger side head replacement (1 year \ 12,000 mile warranty)
3. 400 & a few busted knuckles for the insert, which hopefully can be done without removing the head.
What I'm wondering is if I'm ultimately just going to pop another one and be back to square one.
I would almost go for the head replacement if I could be sure that the replacement head isn't as defective as the one there putting on.
Is it mostly the right side that is prone to this defect, if not, maybe I should just clinch my teeth and go for the factory rebuilt engine.
Would I stand a chance at doing the insert on my own, I'm handier than most, can do breaks and other light repairs, but have not tackled anything like removing a cylinder head.
Any help would be greatly appreciated.
Oh and if there are any other victims of this problem, according to the (4) ford dealers that I spoke to today and the customer realations center, I'm the first one to ever report this problem........ha.
Jeff
Logistics Pro
Joined: Oct 2000
Posts: 3,960
Likes: 5
From: All over Texas
Bad luck as well as bad timing with the holidays.
Personally, I'd go the insert route. There are a couple options, so I'd suggest doing some research. Since this is a common problem, you will find tons of info on this and other Ford truck websites.
Personally, I'd go the insert route. There are a couple options, so I'd suggest doing some research. Since this is a common problem, you will find tons of info on this and other Ford truck websites.
Laughing Gas
Joined: Aug 2004
Posts: 831
Likes: 2
From: Marion,NY
Same thing happen to my 98 5.4 back in August, #3 plug blew out. Tried the insert route first....did'nt work, had to replace the head. Runs like a new truck now, lucky I had bought a month earlier and it was covered under warranty from the Ford dealer. The invoice had a quoted price of $2300.
From what I understand the insert is a temporary fix due to soft aluminum heads.
From what I understand the insert is a temporary fix due to soft aluminum heads.
Senior User
Joined: Jul 2003
Posts: 289
Likes: 0
From: Kansas
Two weeks ago my 99' 5.4 launched a plug while my wife was driving. I didn't know which cylinder had let go, yet on the way home to check it out I stopped at NAPA and picked up an insert kit for $40. I figured I could probably get to 6 of the 8 spark plug bores (with the heads installed), so I figured I had about 75% odds that I could repair it. The bad news was it was number 4. The blown plug trashed the COP but fortunately it didn't take out the threads in the head. I was lucky, but felt I would have had nothing to loose by trying to repair it with the insert... and had several thousand to possibly save!
My suggestion is to pick up an insert kit and give it a try... you're not gonna hurt the plug bore any more than it already is... and if all goes well will save major bucks. You'll find there are quite a few threads about blowouts having been repaired successfully with inserts!
Good Luck
My suggestion is to pick up an insert kit and give it a try... you're not gonna hurt the plug bore any more than it already is... and if all goes well will save major bucks. You'll find there are quite a few threads about blowouts having been repaired successfully with inserts!
Good Luck
Posting Guru
Joined: Jan 2004
Posts: 1,628
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From: South...
I feel for ya'...My 98 Expy is still sittin' in my garage with a fist-sized hole in the right side of the block near the oil pan (number 2 or 3 cylinder launched a piston/connecting rod through it). I've got my local ford dealer down to $2840.00 for a new reman 5.4 with 3 year/36 month warranty. Still trying to decide which route to take. There's a 5.4 on ebay complete (wiring harness, intake, injectors, rails everything) and NOT rebuilt - it's ALL brand new with 0 miles on it for $2895...the clincher is it has NO warranty...don't think I want to drop that kind of dough for something "sold as is".
What do y'all think?
What do y'all think?
Posting Guru
Joined: Jan 2004
Posts: 1,628
Likes: 0
From: South...
Yep...that's my thought too..I can always take the externals from my engine since they're not hurt - that warranty is worth ALOT of peace of mind. They want $1100 to install it. I may let them do that too...the jury is still out on that one.
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Sit. Stay.
Joined: Oct 2001
Posts: 18,308
Likes: 20
From: Washington State
www.timesert.com
The insert is not a temporary solution. It is in fact the solution. If all the sparkplug holes had inserts we wouldn't be having this conversation.
The insert is not a temporary solution. It is in fact the solution. If all the sparkplug holes had inserts we wouldn't be having this conversation.
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Freshman User
Joined: Mar 2002
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From: In a house, mostly
Thanks All
After weighing out all my options, one of which is to not attempt the insert repair on my own, I'm going for the head replacement at the dealer with the 12\12000 warranty.
If I did go the insert route, with the amount of labor that I have to pay out just to get to the #3 hole I'd be inclined to de em all, which adds up to I might as well get the whole thing replaced a warranteed. If I did do just one and another was to blow, the level of I told you so's from the home boss would kill me.
I did ask the good people at Ford if the replacement head will have the same defective design, as much as I beat em up, I could not get them to fess up.
Does anyone know if they beefed up the threads in the replacement heads ?
Replacing the engine sounds nice too, but I'm not feeling all that confident if Ford these days, how well was it rebuilt, was it rebuilt with the defective heads ?
The next step will be to sell it off and buy a Toyota, I hate to do it, but they just don't break like this.
If I did go the insert route, with the amount of labor that I have to pay out just to get to the #3 hole I'd be inclined to de em all, which adds up to I might as well get the whole thing replaced a warranteed. If I did do just one and another was to blow, the level of I told you so's from the home boss would kill me.
I did ask the good people at Ford if the replacement head will have the same defective design, as much as I beat em up, I could not get them to fess up.
Does anyone know if they beefed up the threads in the replacement heads ?
Replacing the engine sounds nice too, but I'm not feeling all that confident if Ford these days, how well was it rebuilt, was it rebuilt with the defective heads ?
The next step will be to sell it off and buy a Toyota, I hate to do it, but they just don't break like this.
Thread Starter
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Freshman User
Joined: Mar 2002
Posts: 33
Likes: 0
From: In a house, mostly
As my truck sat for a week at the dealer awaiting a replacement head, I decided to pull it out of there and give the insert a try. I understand that I have the option to first use the "thin wall insert", then fall back on the "bigsert" if I have to, but timesert seems to recommend using the bigsert the first time around. I'd like to just do this once.
Does anyone have any recommendations on the best coarse to take here ?
Also, the proper part number for the bigsert kit and insert appears to be 5551 and 51459, as shown on timeserts web site.
Thanks All.
Does anyone have any recommendations on the best coarse to take here ?
Also, the proper part number for the bigsert kit and insert appears to be 5551 and 51459, as shown on timeserts web site.
Thanks All.
Thread Starter
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Freshman User
Joined: Mar 2002
Posts: 33
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From: In a house, mostly
I was able to do it on the truck. I moved the wiring block aside, diconnected the heater hoses, and moved aside a few other smaller vacum lines (after lableing everything). The TimeSert kit certainly works as advertised, but I was not able to use the T Bar handle and instead had to use a socket a ratchet on top of the tool holder.
With my modest skills, it took me about 6 hours (3 actual work, 3 head scratching). I suspect a seasoned mechanic could bang this out in a few hours.
By the way, I've run across numerous thread were folks have done the #3 hole on the truck, and I'm sure I even read one where a guy did the #4.
With my modest skills, it took me about 6 hours (3 actual work, 3 head scratching). I suspect a seasoned mechanic could bang this out in a few hours.
By the way, I've run across numerous thread were folks have done the #3 hole on the truck, and I'm sure I even read one where a guy did the #4.