Spark plug blew out

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Mar 28, 2006 | 08:29 PM

iceman7329

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Spark plug blew out

Im posting this for a friend trying to help him out. He has a 99 Expedition with the 4.6, about 2 months ago he had the spark plugs changed, then last weekend the number 4 plug blew out of the cylinder head and stripped the threads out. Any ideas as to what happened?

Mar 28, 2006 | 08:30 PM

iceman7329

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Ok, I think the engine could be a 5.4, 95% sure it is.

Mar 28, 2006 | 08:43 PM

iceman7329

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Alright, Ive read up on this and basicly the guy is screwed for Ford helping him. Time to drill and tap the hole.

Mar 28, 2006 | 08:49 PM

MisterCMK

Fleet Owner

Joined: Mar 2003

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From: Blue Hill Township

yup. Ford won't even admit that they have a problem with the design in those cylinder heads.

Mar 28, 2006 | 08:58 PM

iceman7329

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I really dont know what hes going to do, he had some shop look at it and they said $2000 just to fix that one plug hole. Hes not poor but doesn't have $2000 to throw at it right now.

Mar 28, 2006 | 09:14 PM

aagitch

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I think the shop is trying to rip him off, I don't think it should be that high. Try searching the threads thought I saw something on this that was much cheaper.

Mar 28, 2006 | 09:31 PM

dport

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From: Lenexa, Ks

I had the same thing happen, $2500 for a new head. They wouldn't offer a warranty on the rethread. Mine was 4.6.

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Mar 28, 2006 | 11:05 PM

ford390gashog

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From: Brentwood,CA

go with the timesert kit www.time-sert.com

Mar 29, 2006 | 04:09 AM

#10

slc10844

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Joined: Oct 2003

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From: Baltimore

Quote:

Originally Posted by ford390gashog

go with the timesert kit www.time-sert.com

We use this approach on our fleet of Crown Vics and have had great success. A lot cheaper with less down time.

Mar 31, 2006 | 01:41 PM

#11

Sanchez_315er

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From: Rochester, NY

Stupid question... their instructions don't say anything about removing the head. Isn't there a concern of aluminum getting into the cylinder?

Mar 31, 2006 | 02:03 PM

#12

derherr65

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Joined: Jul 2005

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From: North Texas

Greaseing the tap will capture most of the shrapnel. I wonder if a partial tear down would introduce more dirt/carbon and metal shavings than the tap job alone? Dunno. If you have to drill it to a larger size I'd remove the head.

Mar 31, 2006 | 02:37 PM

#13

jcbfd

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Joined: Oct 2005

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I have a suggestion that you might consider. Try hooking an air source, like a shop vac, to the exhaust. Rotate the engine until air is coming out of the plug hole. Then tap the hole. The air will force the chips out. Be sure to break the chips (back up the tap) frequently. This will only work if you have clear access to the plug hole. And of course, use eye protection.