Spark Plug Blow Out
Postmaster
Joined: Nov 2006
Posts: 4,517
Likes: 3
From: SE Wyoming
It seems to be a result of improperly torquing replacement spark plugs. If you have had plugs replaced and they have not been torqued properly I'd say your odds are ever increasing the more you drive. I didn't lose one until around 225K miles, and that was after 3 or 4 plug changes all done by the dealer. The heads on modulars until sometime in '03 only have 4 threads in them which also doesn't help the issue. Aside from properly torquing if you hear a tick similar to an exhaust leak check the plugs.
Elder User
Joined: Nov 2007
Posts: 768
Likes: 0
From: Michigan
there's millions of these trucks out there without the spark plug blow out. but i do believe that once the ticking sound is heard you can't necessarily prevent it unless you heli-coil or time-sert the spark plug hole, or remove and replace the head with an updated one to prevent it completely.
i had the blow out. had the ticking sound for a good year until it finally popped outta there. then the ticking turned into an old tractor sound as it broke the cop clear off. if it does blow off and you are quite a distance from home. unplug take the spark plug out but leave the cop in the hole. unplug the cop and then unplug the injector going to that cylinder.
i had the blow out. had the ticking sound for a good year until it finally popped outta there. then the ticking turned into an old tractor sound as it broke the cop clear off. if it does blow off and you are quite a distance from home. unplug take the spark plug out but leave the cop in the hole. unplug the cop and then unplug the injector going to that cylinder.
Hotshot
Joined: Jul 2005
Posts: 11,931
Likes: 180
if the plug blows out, you retap new larger threads and install a heli- coil to screw in the bigger thread and it has the standard plug thread in the center. It is a thread insert or repair insert. I would not worry about a blowout. It has happended, but there are millions of F150 out there and only a very small number had a problem.
Senior User
Joined: Dec 2007
Posts: 181
Likes: 1
From: Ashtabula
I just had a plug blow out of my 02 F-250 5.4l, truck only has 61,000 miles--original plugs. It started ticking about 2-3 months before it popped and it sounded just like an exhaust leak. Anyhow I got the CalVan insert kit and had my mechanic use that to fix the plug. Its a very well made insert and the kit is very thought out. So far so good- I've been driving the truck for a couple weeks now and no problems. BTW look at your manifolds and see if you find any broken studs or evidence of a leak(ie soot marks)--if not check your plugs.
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New User
Joined: Jun 2007
Posts: 9
Likes: 0
I just had a plug blow out of my 02 F-250 5.4l, truck only has 61,000 miles--original plugs. It started ticking about 2-3 months before it popped and it sounded just like an exhaust leak. Anyhow I got the CalVan insert kit and had my mechanic use that to fix the plug. Its a very well made insert and the kit is very thought out. So far so good- I've been driving the truck for a couple weeks now and no problems. BTW look at your manifolds and see if you find any broken studs or evidence of a leak(ie soot marks)--if not check your plugs.
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Freshman User
Joined: Jan 2009
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Spark plug blow out
Relaxe,
this can happen to any Ford truck with a Triton Motor. It happened to me 8 months ago.
Check with a few local shops, tell them you would like a quote to repair the spark plug threads. This will normally cost $450-700 to repair. My truck blew the coil at the same time when the spark plug blew. That coil cost another $100.
My truck works fine............I had all eight plugs redone, just for safety.
I only had 66,000 on my truck????
It's all Ford design that causes this problem......they know they built a problem motor part.....
this can happen to any Ford truck with a Triton Motor. It happened to me 8 months ago.
Check with a few local shops, tell them you would like a quote to repair the spark plug threads. This will normally cost $450-700 to repair. My truck blew the coil at the same time when the spark plug blew. That coil cost another $100.
My truck works fine............I had all eight plugs redone, just for safety.
I only had 66,000 on my truck????
It's all Ford design that causes this problem......they know they built a problem motor part.....
aaaahhhhhhhhaaaaaaaa wtf does it make diff for highway driving vs. intown for this to happen
Senior User
Joined: Dec 2007
Posts: 181
Likes: 1
From: Ashtabula
It does not matter. Mine popped out when I was stopped at a stop sign--when I pulled up to the sign all was cool--start to pull away and the truck sounds like a tractor--drove it straight to the mechanic. No point in worrying about it--just check the plug torque if you hear any ticking--it may be too late to save the threads but at least you won't have to replace a broken COP as well.
Freshman User
Joined: Jan 2009
Posts: 36
Likes: 0
don't worry it will pass
I blew my plug doing 30 miles an hour and it sounded like the fan belt blew or a header gasket.........bag, bag
I fracked out.........
Today I understand why it happened, and I hate Ford for not recallng all the triton truck engines///////////
Just carry on and make suer the shop works on all the plugs.........make sure there all tight..........once a year have your plugs checked.........
Drive on..and don't worry..............things could be different..............
I fracked out.........
Today I understand why it happened, and I hate Ford for not recallng all the triton truck engines///////////
Just carry on and make suer the shop works on all the plugs.........make sure there all tight..........once a year have your plugs checked.........
Drive on..and don't worry..............things could be different..............
Elder User
Joined: Nov 2007
Posts: 768
Likes: 0
From: Michigan
the shop i went to originally quoted to fix the spark plug hole using some sort of thread insert at around $200. that is much cheaper and they didn't the easy way by leaving the head on the motor.
it may be the easiest and cheapest but it's not the best. the mechanic who did it didn't have the valves closed so when he tapped the hole for the insert, the tap hit the valve taking small chunks out of it as the valve spun for a little bit. the truck had a noticable miss and then for 500 dollars (after the mechanic paid for half the bill) the head was removed, valve replaced, and the thread insert redone.
my spark plug blew out cruising along at around 75mph. speed doesn't matter, if it's going to blow out it's time will come regardless of speed, the threads don't have a speed that says i'll blow out now.
heli-coil is a way to do it but there is another company who makes the inserts specifically for these trucks. just do a google search and a lot of things should pop up. as for now you have nothing to worry about. the exhaust leak too, nothing to worry about unless it's excessive.
it may be the easiest and cheapest but it's not the best. the mechanic who did it didn't have the valves closed so when he tapped the hole for the insert, the tap hit the valve taking small chunks out of it as the valve spun for a little bit. the truck had a noticable miss and then for 500 dollars (after the mechanic paid for half the bill) the head was removed, valve replaced, and the thread insert redone.
my spark plug blew out cruising along at around 75mph. speed doesn't matter, if it's going to blow out it's time will come regardless of speed, the threads don't have a speed that says i'll blow out now.
heli-coil is a way to do it but there is another company who makes the inserts specifically for these trucks. just do a google search and a lot of things should pop up. as for now you have nothing to worry about. the exhaust leak too, nothing to worry about unless it's excessive.
Junior User
Joined: May 2006
Posts: 63
Likes: 0
From: Calgary, Alberta, Canada
Hello, another question, i'm thinking of getting rid of my 99 for the 03, are there an additional issue. Will my rims fit , and would i be able strip my 99 back to stock and just transfer the parts. Did ford fix the plug problem?