5.4L Crate Engine Updates
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Joined: May 2011
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spark plug blowout
I put the insert in 2years ago. It works great and keeps the truck going inexpensive. I don't drive my vehicles hard at all! As far as a crate motor having the updated heads ytou can order the 2001 model but some mods to the computer need to be done also. Just drop in a new insert it is very easy use plenty of grease on the thread tool to catch the metal shavings! I went through all the same stuff of which way to go. When I do replace the motor I'm going to replace or mod the computer also. I want the newer head design for engine efficiencynot the plug blowout. Heck I was even looking into swapping the engine for the lincoln expedition version with 4 valves per cylinder and change the puter also!
Hi-
I just had a sparkplug blow out on my 1999 5.4L which has about 112K on it. From reading the forum here about spark plug blow outs, this is obviously a well known, and unfortunately, non-rare event for the 1997-2002(3?) Triton engines. Because the culprit is a poor cylinder head design I am not sure what is the best course for repair. I am considering my various options for repair including using aftermarket inserts, replacing the cylinder head, or replacing the engine with a crate engine. I am considering the crate engine option because I don't want to repair the one hole or one head to just have other one go out. The cost of the crate engine is ~$5500 installed, the cost of the cylinder head replacement is ~ $3200, and the cost of the insert kit is order $100 but it is the down time and the uncertainty of the insert repair (or for that matter the uncertainty of replacing the head with the similar casting) that could end up costing me even more. I contacted Ford about whether their crate engine for this vehicle would have updated cylinder heads (i.e, more threads in the spark plug holes) like the 2003+ years. Unfortunately they were not able to answer my question. Does anyone here know the answer or have any other suggestions?
Thanks.
I just had a sparkplug blow out on my 1999 5.4L which has about 112K on it. From reading the forum here about spark plug blow outs, this is obviously a well known, and unfortunately, non-rare event for the 1997-2002(3?) Triton engines. Because the culprit is a poor cylinder head design I am not sure what is the best course for repair. I am considering my various options for repair including using aftermarket inserts, replacing the cylinder head, or replacing the engine with a crate engine. I am considering the crate engine option because I don't want to repair the one hole or one head to just have other one go out. The cost of the crate engine is ~$5500 installed, the cost of the cylinder head replacement is ~ $3200, and the cost of the insert kit is order $100 but it is the down time and the uncertainty of the insert repair (or for that matter the uncertainty of replacing the head with the similar casting) that could end up costing me even more. I contacted Ford about whether their crate engine for this vehicle would have updated cylinder heads (i.e, more threads in the spark plug holes) like the 2003+ years. Unfortunately they were not able to answer my question. Does anyone here know the answer or have any other suggestions?
Thanks.
Posting Guru
Joined: Mar 2002
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From: Willamette Valley, Oregon
this is from wikipedia so it may not be entirely accurate but does explain the head replacement as covered under warranty only and all other repairs are using these suggested inserts
Spark plug issues
2-valve 4.6 L, 5.4 L, and 6.8 L engines found in many 1997–2008 Ford, Lincoln, and Mercury vehicles have an issue with stripped or missing spark plug threads in the cylinder heads. Ford acknowledges this issue in TSB 07-21-2 as well as earlier TSB's. Ford's TSB does not state that this issue is caused by owner neglect. Ford's only authorized repair procedure for out-of-warranty vehicles is to use the LOCK-N-STITCH aluminum insert and tool kit. For vehicles under the New Vehicle Limited Warranty, Ford will only cover the replacement of the entire cylinder head; however, the Ford recommended spark plug service interval extends beyond the duration of the New Vehicle Limited Warranty.[50]
3-valve 5.4 L and 6.8 L engines built before 10/9/07 and 3-valve 4.6 Ls built before 11/30/07 found in many 2004–2008 Ford, Lincoln, and Mercury vehicles have an issue with difficult to remove spark plugs which can cause part of the spark plug to become seized in the cylinder head. The source of the problem is a unique plug design that is made with a 2-piece shell, which often separates, leaving the lower portion of the spark plug stuck deep in the engine. Ford acknowledges this issue in TSB 08-7-6 as well as earlier TSB's. Ford's TSB does not state that this issue is caused by owner neglect. The TSB provides a special procedure for spark plug removal on these engines. For situations where the spark plug has broken in the head, Ford distributes multiple special tools for removing the seized portion of the plug. The multiple procedures required for the different cases/situations of plugs seized in these engines are explained in the TSB. This repair is covered for vehicles under warranty; however, the Ford recommended spark plug service interval extends beyond the duration of the New Vehicle Limited Warranty.[51]
Federal-Mogul, parent company of Champion Spark Plug, and Brisk Silver Racing have introduced a 1-piece machined shell 3-valve spark plugs that addresses the OEM 2-piece spark plug's separation issues.[52][53]
Spark plug issues
2-valve 4.6 L, 5.4 L, and 6.8 L engines found in many 1997–2008 Ford, Lincoln, and Mercury vehicles have an issue with stripped or missing spark plug threads in the cylinder heads. Ford acknowledges this issue in TSB 07-21-2 as well as earlier TSB's. Ford's TSB does not state that this issue is caused by owner neglect. Ford's only authorized repair procedure for out-of-warranty vehicles is to use the LOCK-N-STITCH aluminum insert and tool kit. For vehicles under the New Vehicle Limited Warranty, Ford will only cover the replacement of the entire cylinder head; however, the Ford recommended spark plug service interval extends beyond the duration of the New Vehicle Limited Warranty.[50]
3-valve 5.4 L and 6.8 L engines built before 10/9/07 and 3-valve 4.6 Ls built before 11/30/07 found in many 2004–2008 Ford, Lincoln, and Mercury vehicles have an issue with difficult to remove spark plugs which can cause part of the spark plug to become seized in the cylinder head. The source of the problem is a unique plug design that is made with a 2-piece shell, which often separates, leaving the lower portion of the spark plug stuck deep in the engine. Ford acknowledges this issue in TSB 08-7-6 as well as earlier TSB's. Ford's TSB does not state that this issue is caused by owner neglect. The TSB provides a special procedure for spark plug removal on these engines. For situations where the spark plug has broken in the head, Ford distributes multiple special tools for removing the seized portion of the plug. The multiple procedures required for the different cases/situations of plugs seized in these engines are explained in the TSB. This repair is covered for vehicles under warranty; however, the Ford recommended spark plug service interval extends beyond the duration of the New Vehicle Limited Warranty.[51]
Federal-Mogul, parent company of Champion Spark Plug, and Brisk Silver Racing have introduced a 1-piece machined shell 3-valve spark plugs that addresses the OEM 2-piece spark plug's separation issues.[52][53]
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