truthfuly...I've only heard of the plugs blowing out on the number 3 cylinder....considering the cooling ports....I'd probably go with your original decision between rethread and new heads...I'd choose the new heads...however, as you're asking me about the latter choice......check the clearances between the spark plugs holes and the cooling passages to determine your decision....another thing....aluminum heads, correct?I wouldn't risk the chance of cracking...you'll just have bigger problems later on....

 

Don't be scared of putting in inserts. They are a proven method for solving the problem. They've been used for years (literally) with lasting results. They were also the method of choice by Ford for fixing the problem, prior to '03. '03 is when they started producing heads with more threads.

Stewart

 

The number 3 is common, but for me, it was the number 6 cylinder that blew out.

Stewart

 

I am brand new to the Lightning family--I got a great deal on a truck for my son to take to college. I have not done any work on it yet, but it just developed a bad miss which coded out to a 306 or a miss in the #6 cylinder. All this talk of plug ejection is scaring me--I haven't heard of this yet. My suspicion is a bad COP unit--isn't this more common than the plug issue? Should I replace them all while I have it down? Where do you get the extenders to make this easier next time?

aj

 

http://www.consumeraffairs.com/news04/2005/ford_spark_plugs.html

http://www.consumeraffairs.com/automotive/ford_spark.html

http://www.consumeraffairs.com/news04/2006/01/ford_truck_engines.html

A very common, very well known problem with the Ford modular engines up to and including the 2002 model year.

Nope. The Ford Motorsport COP's are a very good, well made unit.

When I shot my plug, I replaced only the one COP. All my other COP's were fine and knowing they are well made, I saw no reason to replace any others.

If you're talking about the coil pack screw extenders, there is only one place to obtain those, at Madenterprise.com specifically, http://madenterprise.com/F150.htm

Stewart

 

Hey guys, I have just been reading your posts. I do have a few questions. Is this plug problem a year specific problem? I have a '01, and my Dad has an '00. We both track our trucks and run hard. We do change plugs often, could you explain a bit more about what causes the "blow-out".

Ok, on to the other reason I am posting. I am kinda new to forums, so I don't know about what others are saying about RPM. Between my Pop and I we have bought 2 Diablos, 2 4LB lowers, many belts, 2 thermostats, traction bars, 2 intakes (1 K&N, and 1 AEM), many sets of plugs, boost gauge, I just bought the accell COP's w/ granatelly boots & connectors ( will let you know how they run as soon as I get the truck out of the shop). I have NEVER had a problem with RPM. I have had nothing but good experiances with them. HOWEVER, there are some real son of a .......s, that work there. If Jeff answers the phone hang up and call again. The guy I worked with most reciently is Kris. He went above and beyond the call to help me. So that is my $.02.

As far as the headers, the Bassani X no cat system is what I run and love it. It sounds super. However, if I were doing it over again, I might go with long pipes because of the growth potential you get with them. If you dont plan to go over 600Hp I think the shorty's are the ones for you. Hower, if you ever have to change the manifold gaskets just pay someone else to do it, it sucks.

 

Running the truck hard, or even being supercharged, has nothing to do with the plugs blowing out of the heads. The plugs blow out of the naturally aspirated 4.6L and 5.4L engines as well.

What causes the plugs to launch is a lack of an appropriate amount of spark plug threads in the heads. Starting with the 2003 Lightnings (only the '99 - '02 Lightnings have to worry), Ford changed the heads, putting 8 to 10 spark plug threads in the heads.

Install your plugs on a cold engine, torquing the plugs down to 13ft pounds, and then check them every 6 months or so and you shouldn't have a problem.

As for RPM Outlet, I have a couple friends who have had the same good luck you've described, but they are in the very small minority. There are way too many others on the Lightning boards that have been screwed over.

Stewart

 

I also forgot to mention, check eBay for another set of stock heads. Guys are always posting take of heads from L's that they are upgrading to something else. A few months ago I found a guy who was selling his complete S/C with heads, injectors, fule pump, water pump for a buy it now price of $1000. He said the truck only had 30k. Just a thought

 

Well the verdict is in. The extended warranty that I bought when I bought the 2000 Lightning from the Ford dealer paid off as the SVT tech at the Ford place here in New Orleans pulled the plug out of #6 and the inside of the plug was gone. The threads were intact and the plug was in the cylinder, but the contact was disintegrated inside the motor. No compression in the cylinder, so the engine has to come out for a makeover.

Bad luck after having the truck for 3 weeks, but good luck that the warranty should cover most of the cost of the repair. The tech said they would recommend a new 5.4 in a crate--that would be great fortune with 93k miles on the truck.

I appreciate your wisdom Stewart--thanks.

allen

 

Sorry to here about your misfortune but that's Great you might be getting a new motor.
Those warranties to pay off sometimes!