......on the way home. 2003 F250 5.4L 4x4. 106K on it.

It blew out, broke the COP mount bracket and boot (ruined the COP) and the plug ended up resting on the cylinder head. I had a plug job done about 5 months ago and thought it may just be that they didn't torque the plug down and it finally worked its way out. The threads on the plug look fine. Luckily, I was turning into the neighborhood when it blew.

While searching tonight on how to replace the COP, I came across the info that it was a design issue. It appears that there is an issue with 1999-2004 Ford motors blowing plugs and ruining the cylinder head.

Now I'm worried that I have a fooked cylinder head and it's going to cost alot to get it fixed. Has anyone had this happen and what route did you take??

I haven't had a chance yet to see if the threads in the cylinder head threads are stripped. I had to work today so I just drove my wifes Jeep. I'll take a look at it tomorrow morning.

Also, how do I replace the COP??...IE how does that assembly work? I assume you drop the plug into the hole, thread it in (if I have any threads left) (10 ft/lbs right??) and then install the boot from the COP over the plug, and bolt down??

Thanks in advance for any advice or help.

 

The threads in the head are probably fine. I'm guessing it wasn't torqued. If not it can be repaired simply at a cost of around $200.00 for a kit from timesert...I thought in 02 that ford went to more threads in the head..12 ft lbs is the torque with some anti sieze.


Dick

 

Here's to hoping the threads are still good....

There appears to be issues with the '03's as well.

REMOVED by moderator krewat - we don't need that link

 

Forget that consumer affairs website - it was started by a bunch of lawyers.

Chances are, the threads in the head are gone. If it lasted this long, chances are, the threads just rotted to the plug and when they changed them, they did it the brute-force way, and took out the threads with the plug.

There is an insert kit available to fix the threads with the head ON the engine. Ford dealers can now get the kit and fix it the easy way.

Timesert was the first on the market with an insert kit.

As for updates to the heads, I've mentioned it in the V10 forum quite a few times, but here's the schedule for spark plug thread changes for the various modular engines.

December 1996 - 4.6L 4V alignment feature added
February 1997 - 4.6L 2V head alignment feature added
September 2000 - WEP (Windsor Engine Plant) 2V head alignment feature modified (4.6/5.4/6.8)
November 2002 - WEP introduced long thread heads on 2V (all)
May 2003 - REP (Romeo Engine Plant) introduced long-thread heads on 4V 4.6 and 5.4
November 2003 - REP introduced long-thread heads on 2V and modified alignment feature

I found this information in a Ford document I had access to a while back...

The factory torque-down procedure was also modified sometime before the "alignment feature" was added, but I don't remember when exactly.

 

Well, the threads are gone.......

 

I used helicoils on mine with longer threaded plugs (3 so far) they blew around 80,000 (right after the warranty expired ) Later had to replace one head for other reasons but they were holding fine. The COP installs just like you said, fairly simple. In the future, be alert for loud ticking sounds (similar to an exhaust leak) as this is the sound they make before they actually blow out. IFRC, we changed all the rest of plugs to longer thread, but that was 5+ years ago so I can't be sure. No problems since, but I do carry a helicoil and extra COP just in case.

 

Chin up guy. I did this repair last week, also the #3. Timesert kit #5553. Worked like a charm, took me most of the afternoon. The kit consists of some excellent looking tools. The web site has an excellent video.
The only part I was concerned about was their insistence that both valves be closed during the procedure. I was fairly sure mine were but didn't have a warm fuzzy.
Look for my kit on eBay. I'll be asking around $325, comes with seven inserts.
Userid neksiwel
Ken