Sorry, about this post being so long, just want to try to get all the details in. I bought my 2002 5.4 EXPY around a year ago. It had 68k miles on it when I bought it. About a month later, it started missing on me and the Service Engine light came on. I took my truck to Advanced Auto to have the code read, turned out to be a misfire on the #3 cylindar. So I bought plugs and replaced them all myself. (I did not get new boots or COP's, just the plugs). I then got on the internet and read about all the troubles people were having with plugs. So begins my worrying over buying a busted truck. The truck missed a time or two after that, but cleared up, so I figured all was good.

I have a 31'6" travel trailer and towed it last summer with my EXPY with no issues, did not tow far, about 25-30 miles. And have used my truck for a few road trips (kids are involved in sports) and had no issues until now.

About a month ago, it started missing again, Service Engine light came on, had it read again and this time it was the #4 cylindar. So I figured that the COP must be bad. I bought a new COP but did not get around to putting it on. The missing stopped until this past Sunday, I was at work and was going to go get some lunch when I started it up and <POP>. I popped the hood to discover the #4 COP and plug had blown. I called a tow truck and had it towed to my trusted mechanic, and took the plug back in to work with me. As I examined the plug, it looks like that there were only 3-4 threads that were holding the plug in. There was no sign of stripping. There was no shavings from the head on the plug. The last 3-4 threads were 'clean' while the rest of the plug/boot was pretty dirty. So I thought that I must have not got the plug on tight enough and it just worked itself free. So that night I thought I would see if I could put the plug back in, sure enough it started threading right away. So I pulled that plug out and put a new one in. Luckily I bought that COP earlier and put it on. Fired the truck up and it sounded good as new. Drove the past couple of days and felt great. I drove it into work today and thought I felt it miss once on the way in to work and then again on my way home from work. The Service Engine light did not come on. And other than those 2 times, it drove great.

Now, I have a trip I need to take this weekend and am a bit timid about driving my truck. Has anyone else gone through this? Anyone got any advice that could ease my mind about driving it?

 

If it blew the plug out the first time I would be concerned, if you do have threads left there isn't many. When these plugs are changed out they can't be tightened up as much as one would normally think. Over tightening of these when they are changed out is one of the main reasons of the plug blow out. There is a kit that's made that has a threaded insert to repair these. http://www.timesert.com/html/triton_repair.html

 

Thanks for getting back to me on this. I'm not sure, but can a compression test tell me if there is a problem with that (or any) plug? Or do I play the waiting game to see if it blows again? I really trust my mechanic and he has mentioned to me before ( when i first ran into the problem) about the inserts you mentioned.

 

No, I don't think a compression test would give you any advance warning of a problem. I think however I'd do the insert for sure on the one you had blow out instead of waiting for it, because it never fails, it'll go out at the worst time.

 

Thanks again! I love the truck, just wish I had the peace of mind knowing that I could hop in it with the kids and go and NOT worry about getting stranded.