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Would anyone know if it's possible to install Time Serts into every plug hole to prevent the spark plug blowing out before it happens? Would the plug hole have to be bigger or can you just screw in the insert when you do a tune up? Do the threads have to be stripped in order for the inserts to fit? This may seem stupid to some people but I believe in preventing things as serious as this before something happens. Thanks.
I am sure that the hole would have to be enlarged.
If it ain't broke, I wouldn't try to fix it. Most 5.4's never have this problem, for every one that you read about on here, there are thousands of others out there that have no problems. This site represents a small percentage of the trucks out there and most are trouble free.
Time Sert does make a spark plug kit. You will have to drill out and and enlarge the hole because the timesert insert will bring the oversized hole back to original dimensions. Time Fastner's website is www.timesert.com
Check the misc. kits for the spark plug. You have to call for prices (800) 423-4070.
I know nothing about the newer fords so I'm assuming this engine is aluminum? If the hole isn't stripped then leave it be. The best preventative measure you can take is to not overtighten your plugs and don't use anti-sieze on the threads.
The spec for spark plugs requires neverseize according to the dealer. I agree with the comment about overtightening. The bigger problem is that there's only 4 threads to catch, and nearly any level of cross threading will screw you.
With the hope that it never happens to you, I would wait until if/when it does. I know some members of this forum have inserted HeliCoils/Time Serts into the cylinder heads while still mounted on the engine, but if you're a bit careless and allow aluminum shavings into the cylinder, you risk gouging the cylinder wall and losing compression, power and fuel economy. The least risky method, IMHO, is to pull the cylinder head off the engine, not a pretty task on an overhead cam engine that's a bit buried under the cowl.
I'm no expert in these things, but IMO it's not a common problem. It has been known to happen, but I believe you have a higher risk of breaking something trying to prevent it than you do of having a truck blow a plug. With over a million of these trucks on the road, sure you're gonna hear of a few problems, but the percentage is very low.
The fact that Ford re-engineered the head to 10 threads in the sparkplug hole in 2002, up from 4 threads is a pretty clear indication that this is a pretty common problem. My dealer here sees 1 blown plug a week with a $3500+ fix.
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