Well folks, Ive read about it on forums like this for years and it finally happened to me.
I had the spark plug on the #3 cylinder of my F-150 blow out. I was driving to work on Friday morning and all of the sudden I started to hear this, "POP, POP, POP". At first I thought maybe flat tire, but the pop continued while the truck was parked idling, so I figured it was a blown sparkplug. I drove to work slowly and during my lunch break I took a look and sure enough, it was blown out.
So, I went down to the local Carquest, bought a Helicoil sparkplug thread repair kit and my brother and I installed a helicoil this weekend.
Although its a job I hope I never have to do again, it really wasnt all that bad.
We tapped the hole with the tap, started the truck to blow out all the metal shavings, put the helicoil on a new sparkplug to install it (we couldnt get the sparkplug and helicoil to seperate while the helicoil was inside the engine, so my brother just tightened it as hard as he could with a 6" ratched), then we let the truck sit overnight so that the high-temp silicone could cure and when I started the truck today at noon it seemed fine.
Im a little bit concerned about the fact that we didnt use the setter tool to set the helicoil, but I dont see how we could have gotten the coil and the sparkplug apart while the coil was in the engine, so I think we did the best we could.
My father and neibor are both Ford techs and they said that if we tightened it as hard as we could with a 6" ratch, its probably not going to back out.
So, thats where things stand as of now. Im hopefull that my truck wont give me any more grief like this, but we shall see.
So, for those of you who are worried about the plug blow-out, dont think that just because you blow out a plug that you have to spend $1,500 for a new head. Just install a helicoil.

 

well it sucks that it happened. when had your plugs been changed?? is this your first major trouble with the truck?? least you got it fixed and i hope its happy sailing from here!!

 

I changed the sparkplugs at about 112,000 miles and they were torqued to the proper specs.
This is the first major trouble with this truck. In the past Ive had a few issues here and there, but nothing major (just routine maintenance).
Thus far this truck has been pretty good (knock on wood) and Im hoping that I dont have any more major issues with it.
A couple weeks ago I had the driver's side inboard tierod end break on me, so Ive had a stretch of bad luck with this truck lately.
At 180,000 miles though, I cant really be too surprised that its starting to give me grief though.
I still think its BS that these trucks have this issue. IMO, you should be able to take it to any Ford dealer and at least have a helicoil installed for free. Its not as if its just Ford though, all brands have issues and it seems like none of them want to face them and make things right with their customers.

 

i think you've done well for 180k miles... built ford tough is more than a slogan, its a lifeline...

 

Yeah, Im still a little bit concerned that it will pop another plug or that the helicoil will back out on me though.
All in all though, my truck has been good to me (knock on wood).
My father works for a Ford dealer and they have done quite a few helicoils as a low-cost repair to this problem. He tells me that they havent had a truck come back yet with a blown-out helicoil, so Im hopefull that everything will work out.
Im planning on buying a used Focus in the next year or 2 and keeping my truck as my beater/wood hauler/snow vehicle, so even at that point even if it starts to give me more issues it wont be the end of the world. At least I will have the Focus, so I will still be able to get to work. You know, thats the main concern right now. If my truck goes down, Im pretty much screwed as far as getting to work goes.

 

I have been experimenting with the use of helicoils in place of the weak threads on a couple of PI heads and I know they will be a permanent repair. The repair effort and costs were much less than expected. I decided to use red thread locker instead of the RTV silicone. I simply felt it was designed for locking threads where RTV isn't. I also used alot of thread anti-seize on the sparkplug before installing the helicoil. I allowed it to dry for awhile and the sparkplug was easy to remove. I then used the expander to lock the insert in place. I do have a couple of questions for you.

1) Did you use a new double platinum spark plug when you installed the helicoil?
2) Did you use anti-seize on the sparkplug threads?

I'm betting that if you used a new plug along with anti sieze, that you will not have any problems with this repair. I would also bet that you will be able to remove the sparkplug if you ever have to tune the truck again. With 180K miles, you are probably in good shape for a very long time.

 

New sparkplug (the one that was in the truck was trashed) but we didnt use antisieze. We sprayed a little oil on the threads between the helicoil and the sparkplug hoping that would allow them to seperate once the helicoil was inside the engine, but that didnt work out.
If the helicoil comes out with that sparkplug when I change plugs, I will just reinstall it again.
We did end up using an Autolite Copper Core sparkplug (103 instead of the recommended APP103). Thus far the truck seems to be running fine and isnt throw any codes (knock on wood). I went to the auto parts store and told the guy what I needed, told him what truck it is and what engine it has. It wasnt until we went to install the helicoil that we noticed it wasnt a double-platinum plug.
From what I understand, the copper plug will wear out quicker, but I had planned on putting new plugs in at 200,000 miles, so I think it will be OK.
My father works in the service department of a Ford dealer and I asked him if the copper core plug would work OK and he said it would be fine, just that it would wear out quicker than a double-platinum.
I was a little bit concerned about the fact that we didnt use the setter tool to expand the top of the helicoil and that we used a copper core sparkplug, but thus far (knock on wood), it seems OK.

 

Octane,

I think you have the right attitude about the repair. Many of the threads I have read over the past few weeks are from owners who were worried sick about spending thousands of dollars to repair the problem. I also think that alot of them are getting lured into paying big bucks for Timeserts, Lock-n-stitch, etc. I know the other options are very good repairs, but the do-it-yourselfers can simply make the repair using the Helicoil for alot less money & time. I also think you will be fine with the copper core plugs and you might be surprised at how long they will last.
There is another fellow that appears to know what he is talking about, jbrew, and he recomends the Global COPs from Ebay, and he strongly recomends using Motorcraft replacement platinum plugs. I used his advice about the COP's and it completely eliminated the light miss I was having. However I used the APP103 double platinum Autolite plugs instead of the Motorcraft and they are working fine.

Stay in touch!

 

Yeah, Im trying to keep a good attitude about it. I think the whole deal is a bunch of BS and that Ford should be stepping up and helping us out, but Im going to do the best I can.
I could get all mad and say Im done with Ford, but my truck has served me faithfull for the past 7 years, so I cant complain.
Besides, if I bought a Chevy or Dodge Id have way more problems to deal with and I dont want to buy an import.
Im planning on buying a 2-3 year old Focus next year (planning on keeping my truck as a winter beat/wood hauler), so even if I have more problems in the future with my truck, it wont be the end of the world.
My father works at the Quick Lane of a Ford dealer and he told me they have done quite a few helicoils in Triton engines and they are yet to have one come back with a helicoil that failed, so Im hopeful that everything will work out.

 

Most of the trucks that have the sparkplug-spitting problem are getting to be a few years older, and with falling values, I can see a lot of owners simply throwing in the towel when faced with a head-replacement job if one of the plugs blows out. And, with more experience in the field with various helicoil-type repairs, I'm thinking that there will be way more mechanics who have experience with this type of repair and who will be glad to do one for you.

Even the guy with the million mile 5.4 liter van finally blew a plug--check his forum page link below. He got it fixed for $150 and is back on the road.

http://pub30.bravenet.com/forum/2575...fetch/1164804/

 

wow...a million miles... i wish i could stay interested in a vehicle long enough to see that kind of service!!

 

Octane,

Do you or your father have any suggestions for where to purchase discount FORD parts on the WEB? I need a new clutch for my clutch fan and the local dealer quoted over $100 for the part plus $150 labor.

Also, as you can determine from my handle, we used to own a 2002 Focus and we really liked it. Got around 28 - 30 MPG. We traded it last year but I kept the handle.

I had a 94 Ford extended cab pickup w/302 for over 10 years before recently trading for a very well cared for 02 extended cab, XLT, FX4 with the 5.4L. I couldn't believe how much Ford improved the pickups since my old 94. I drove Tundra's, Chevy's, and Dodge pickups before purchasing my 02 F150 just to make sure I was a real Ford guy and I am. None of the other trucks drove as nice or had the low end torque that my Ford has. I also own a 2004 Taurus and my baby, a 84 Mustang convertible which I have restored. I also built the 347 and AOD tranny myself.

 

Sorry, I dont know of any sites that sell discount Ford parts. All I think is maybe try Ebay.

 

I can help you with discounted Ford parts. Either PM me or contact me through my site. Looking forward to helping you with your needs.

~Kenny

 

Y2K,

Thanks a bunch! I will be sure to bookmark your website and shoot you a note when I need original replacement parts.