Spark plug blow-out
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Joined: May 2010
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Spark plug blow-out
I recently had the plug on the passenger side/rear firewall blow out. After a AAA call & a tow, I had it to my mechanic. He told me that it was likely the result of an improperly seated/tightened plug when I had them changed in late Aug. of '09. He also told me that 'a couple' of the top threads were compromised, & that he wasn't sure if he'd be able to seat a new plug properly. A few hrs. later, he called & told me he'd been successful & threaded a new plug in. He told me it would only cost me about $90. When i informed him that his shop had replaced the plugs last year, he told me there would be "no charge then". He apologized for the incident, and I went on my way. The next day, he called me to see if the truck was running ok. I told him it seemed to be. He's never called me like this on previous work, and I believe he was also concerned, if not a bit worried.
I told a friend of mine about the incident, & he was very concerned, telling me he'd read about this problem in the aluminum heads, and that there were not many threads to begin with on the 03 engines.
I am nervous about this; it hangs in the back of my mind on every trip. I have always trusted this mechanic.
Is there something I could or should do?
I told a friend of mine about the incident, & he was very concerned, telling me he'd read about this problem in the aluminum heads, and that there were not many threads to begin with on the 03 engines.
I am nervous about this; it hangs in the back of my mind on every trip. I have always trusted this mechanic.
Is there something I could or should do?
Cargo Master
Joined: Apr 2003
Posts: 3,476
Likes: 224
From: Frequently frozen MN
Depends on your engine. The 5.4 - 3 valve initially had problems with insufficient threads, and some blew out. The first attempted correction resulted in plugs that often broke apart when removal was attempted.
If you have one of the early versions of the 5.4, plug blowout was an issue. The plugs were supposed to be carefully torqued to a fairly low value. (I think 12-14 ft lbs).
Apparently fixed correctly in 2007.
Search on plug blowout and you should find a lot of info.
In any case, it would probably be worthwhile discussing this with your mechanic. He sounds like a decent sort, and I'm sure that he's worried that you might sue him. If it were me, I'd just say that I was concerned, and ask for his opinion on the problem. (Just a suggestion).
If you have one of the early versions of the 5.4, plug blowout was an issue. The plugs were supposed to be carefully torqued to a fairly low value. (I think 12-14 ft lbs).
Apparently fixed correctly in 2007.
Search on plug blowout and you should find a lot of info.
In any case, it would probably be worthwhile discussing this with your mechanic. He sounds like a decent sort, and I'm sure that he's worried that you might sue him. If it were me, I'd just say that I was concerned, and ask for his opinion on the problem. (Just a suggestion).
Senior User
Joined: Feb 2009
Posts: 491
Likes: 4
From: Southern Illinois
I'd ask him if he'd be willing to recheck the torque on all the plugs to make sure they are not over-tightened either. Or, do it yourself and you'll know its right in your mind.
I have a 97 Expedition with the 5.4 and after a lot of research here on FTE, I replaced my plugs and coil packs on my own and torqued each plug to 12 ft lbs. That's right in the middle of the torque range determined by Ford. I have put over 7k miles on my engine since then with no problems. (knock on wood)
The plug blow out issue is debatable. Some people say its a defect while others claim its user error that contributes to this - such as wrongful installation.
I have a 97 Expedition with the 5.4 and after a lot of research here on FTE, I replaced my plugs and coil packs on my own and torqued each plug to 12 ft lbs. That's right in the middle of the torque range determined by Ford. I have put over 7k miles on my engine since then with no problems. (knock on wood)
The plug blow out issue is debatable. Some people say its a defect while others claim its user error that contributes to this - such as wrongful installation.
Elder User
Joined: Jan 2008
Posts: 605
Likes: 1
Many shops of are aware of the design defect and pre-warn customers before the work begins that damaged threads and blown out plugs are common the Ford engines that have only 3 or 4 spark plug threads. They won't be responsible for problems while removing the plugs. The customer is given the chance to go elsewhere. If I had a mechanic who could see all the way down in that recessed plug hole and see damaged threads I wouldn't change mechanics for a very long time. This poor design should not have made off of the design table let alone onto the assembly line. Then Ford topped this with the two piece spark plug that breaks in half as you remove it. As long as it makes it past the life of the warranty Ford is good with it, but if you plan to keep one of these engines going for the long term you're going to need some luck to avoid having these problems. P0401, P0171, P0174 along with COP and spark plug changes are a real money maker for indepenant shops once the warranty expires.
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