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2001 F-150 5.4L
Driving down the highway yesterday my truck started making a popping noise (sounded just like an exhaust leak). The engine light came on and I put the code reader on it. Misfire #3 cylinder. Pulled the COP, the boot was melted. The spark plug looked like it had shorted somehow as there was a melted spot right obove the threads.
I replaced the plug and COP, test drove it a few miles, everything ok. The next day I drove it about 20 miles and it started missing again. I pulled the same COP and it was melted again. I have not pulled the plug yet.
Well I'm no electrical expert, but if the same one keeps melting it sounds like it is grounding somehow. Are you using the dielectric grease? I would check the wires going into the COP to see if anything looks grounded. Did you blow out the plug hole to make sure nothing is in there that could be causing it to ground?
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