Spark Plug Blowout!!
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Elder User
Joined: Feb 2005
Posts: 630
Likes: 1
From: Central PA
Spark Plug Blowout!!
We were 200 miles from home when my 98 5.4 blew a spark plug. Third back on pass. side. I tried to put it back with no luck. I ended up leaving it at a mechanic and borrowing a family member's vehicle to get back home. I spoke with the mechanic this morning and he didn't sound very suprised when I was describing what happened. Now I'm waiting to hear back from him on how much $ this will cost me. I just did a search on this forum and now I'm scared. I guess the worst case would be a head replacement. And at best they can helicoil it in place. I can't wait to see this bill.
Junior User
Joined: Aug 2004
Posts: 69
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Spark Plug Blowout
Do you have any history on the vehicle,were the plugs motorcraft?I've read the same horror stories about spitting out plugs.From what i have read the design on the head uses only a few threads for the plug to screw in.If they are not torqued down correctly and not using Motorcraft plugs they like to spit out.
There are thousands of posts about this and it's a shame ford will not stand by there products and issue a recall on this.
There are thousands of posts about this and it's a shame ford will not stand by there products and issue a recall on this.
Fleet Owner
Joined: Apr 2008
Posts: 24,316
Likes: 5,127
From: 0,0,1
Direct the mechanic to this site. The hole can be repaired without removing the head.
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++ Ford Spark plug Repair ++, ford spark plug blow outs, blow out spark plug ejection blow out, blown out sparkplugs, ford stripped spark plug, ford sparkplug blow outs, ford spark plug blowouts, ford defects, ford spark plug repair ford, ford spark
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Elder User
Joined: Feb 2005
Posts: 630
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From: Central PA
I googled 5.4 blown spark plugs. Wow. There are so many complaints. I even found complaints on consumeraffairs.com about this. I called my local dealer and one person said they are aware of this happening on F-150's. Then another guy tried to downplay it and said he has seen it a couple of times but its not a common problem. I wonder if someone at Ford is keeping track of this problem. Yes it sounds like an expensive recall, but how long can this go on for? And after I get my truck fixed, who's to say another one won't blow out. As a lifelong Ford guy, this is starting to turn me!!
Elder User
Joined: Dec 2003
Posts: 590
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From: shelocta, pa
here is the link for time sert. my friend blew one and repaired it himself.
++ TIME-SERT SPARK PLUG REPAIR KITS - FORD ++ Spark plug ejection problem blown out blow outs spark plugs blown out spark plugs, ford blown out spark plugs blow out spark plug defect
++ TIME-SERT SPARK PLUG REPAIR KITS - FORD ++ Spark plug ejection problem blown out blow outs spark plugs blown out spark plugs, ford blown out spark plugs blow out spark plug defect
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Elder User
Joined: Feb 2005
Posts: 630
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From: Central PA
I just got a call from the garage. Its gonna be $443. Helicoil and 2 bad COP's. This guy says its the 5th one he has seen in about 2 years and they have all been the same one, passenger side, 3rd one back. I must say, I got off easy. I've read the horror stories.
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Elder User
Joined: Jul 2004
Posts: 637
Likes: 4
From: Media, PA
Yeah, I'll say you lucked out. Nice honest garage and they didn't try telling you that you needed an entire head assembly. I see you're from central PA. What town is this garage located in?
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Elder User
Joined: Feb 2005
Posts: 630
Likes: 1
From: Central PA
This actually happened in Long Island, NY while we were visiting family. I had to leave it there and borrow my sister-in-law's van to get back home. I took it to a mechanic that was recommended by a relative. So now its fixed and I have to drive back on my day off and return the van and drive my truck back. Its about a 3 1/2 hr drive 1 way.
Senior User
Joined: Feb 2009
Posts: 491
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From: Southern Illinois
I know this thread has been here a while, but I'd like to add something. I picked up my 97 back in the end of January all I thought about was changing the plugs for myself and ensuring that they were all properly torqued since my plugs were original - even at 108,000 (prev owner said). When I removed my plugs, all were fairly snug/tight except number three and seven. Number three I did and seven my dad was actually turning the wrench while I grabbed a water. The remaining cylinders took a fair amount of elbow grease to break them free. Number 3 hardly took any - it honestly surprised me. My dad claimed 7 did take much either but I didn't feel it. There is something about three that makes me wonder why that cylinder and not 4 or 8? Those two were the most difficult to apply proper torque to.
New User
Joined: Oct 2008
Posts: 17
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i had this happen to me on my 97 expy and i found my repair kit at napa or i am sure anyone who deals with dorman products . i will tell you it is one slick repair kit and i would use it again. www.dormanproducts.com
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part # 42025 For replacing stripped plug sockets on the following Ford engines using spark plugs with 14mm threads, .708" reach, 5/8" hex, tapered seat: 4.0L, 4.6L, 5.4L, 6.8L
Detailed Applications
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part # 42025 For replacing stripped plug sockets on the following Ford engines using spark plugs with 14mm threads, .708" reach, 5/8" hex, tapered seat: 4.0L, 4.6L, 5.4L, 6.8L
Detailed Applications
Junior User
Joined: May 2009
Posts: 56
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Hate to pull up an old post, but I blew out the second plug on my 99 5.4 today on the way home. I left the truck and made the wife come and pick me up. First one was 3rd one back on drivers side, Dealer charged me $600 to repair it on the motor, this one is the rear one on passenger side, I can touch it but it is burried back there.
Truck has a bunch of miles, 240,000 but is still in relativly good shape. What options do I have?? replace heads or thread inserts?? which one should I go for? this is the second time it has happened. Any guess as to costs for replacement heads? Is that the best way to go??
Sorry, lots of questions but I never had a place that could give me a straight answer except the dealer and I believe he has taken enough of my money.
Truck has a bunch of miles, 240,000 but is still in relativly good shape. What options do I have?? replace heads or thread inserts?? which one should I go for? this is the second time it has happened. Any guess as to costs for replacement heads? Is that the best way to go??
Sorry, lots of questions but I never had a place that could give me a straight answer except the dealer and I believe he has taken enough of my money.
Fleet Owner
Joined: Apr 2008
Posts: 24,316
Likes: 5,127
From: 0,0,1
If you have the tools and know-how to change the heads I would go that route. For a couple of hundred bucks per head (rebuilt) you end up with a valve job in the process. Check eBay, there are some good deals on there, but get your casting number off the heads first, you'll need them.