View Poll Results: Spark plug blowout, has it happened to you?
Yes, on 5.4 engine.
64
28.70%
Yes, on 4.6 engine.
10
4.48%
Yes, on 6.8 V-10 engine.
4
1.79%
Never happened, knock on wood 
.
.
145
65.02%
Voters: 223. You may not vote on this poll
Spark plug blowout Poll, how many have had this happen?
Junior User
Joined: Nov 2008
Posts: 60
Likes: 0
From: Wadsworth, Ohio
I hear it is. Anybody else?
Moderator
Joined: Dec 2001
Posts: 22,436
Likes: 17
From: Louisville,Ky.
Proper torque and anti-sieze on the plugs and you should be fine. It is a small percentage that actually fail. Our 2000 5.4L in a F250SD where I used to work had over 115,000 miles on the original plugs with no problems.
Junior User
Joined: Nov 2003
Posts: 69
Likes: 1
From: ny
yeah , finally happened , 3rd one back , pass side.left it in garage 3 days , while my blood boiled, used kd kit , took all of 45 minutes to fix included r&r fuel rail...as far as steel insert in aluminum head, i'm origanally from south shore of L.I. and used the KD inserts on outboards (probably 500 or so), and never once had a problem....anybody swap out a 3 valve into an earlyer 2 valve truck, can't find any info on site.. love my 01 SD, and would rather cange to later motor .4 thread plug holes scare me a little.
FTE Leadership Emeritus
Joined: Jul 2002
Posts: 42,561
Likes: 423
From: Long Island USA
hangman, I too live on the South Shore 
You can go to the later heads, 2003 model year or so, through 2004, that have 7-8 threads for the plugs. Either that, or do inserts on all the plug holes.
You can go to the later heads, 2003 model year or so, through 2004, that have 7-8 threads for the plugs. Either that, or do inserts on all the plug holes.
New User
Joined: Mar 2007
Posts: 18
Likes: 0
Well you can add me to the list now. I just lost my first plug on the 5.4L in my 98 Expedition. It has 139k on the clock and it is the fisrt plug I've failed since i've owned it (~50k miles).
I was hesitant but I bought the Timesert kit (p/n 5553) from Fastenal for $331 out the door. I initially was ticked that it cost that much but after getting and using the kit I can say that it is very well designed. It took me about 1 hr to get to the offending hole and get the insert installed. I cannot comment on the durability yet but the directions were very clear and complete and went exactly as described. I recommend this to anyone who has access to an air compressor and air ratchet.
Steve
I was hesitant but I bought the Timesert kit (p/n 5553) from Fastenal for $331 out the door. I initially was ticked that it cost that much but after getting and using the kit I can say that it is very well designed. It took me about 1 hr to get to the offending hole and get the insert installed. I cannot comment on the durability yet but the directions were very clear and complete and went exactly as described. I recommend this to anyone who has access to an air compressor and air ratchet.
Steve
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Senior User
Joined: Feb 2008
Posts: 201
Likes: 0
From: Colorado
#6 on the wife's 2002 Expo. Used the Calvan 38900 kit. All went well no hassles. But I wouldn't want to try the job without air and a good air ratchet! Also did 2 for my buddy that has a shop. 1 2001 SCrew #6 , and 1 1998 SCab #3. All were the 5.4 engines.
New User
Joined: Nov 2007
Posts: 10
Likes: 0
From: Northern NEW YORK
5.4l 3v Spark Plug Blowout
I had my #4 plug blow out, Come to find out that the injector was stuck open. When the dealer put a new plug and injector in the connecting rod broke and jammed up against the block so ford is replacing the short block, i thought i was going to have to pay for a new head cuz they thought the threads ripped out!!! i am going to trade my truck in so i don't have to deal with Ford's dumb design with the sparkplugs and injectors. i'm better off with my Dodge!!!
FTE Leadership Emeritus
Joined: Jul 2002
Posts: 42,561
Likes: 423
From: Long Island USA
Again, I must remind everyone who has NOT had a problem to VOTE in this poll to keep things somewhat realistic.
RAMRODMUDDER, stuff happens. Was it covered under warranty? Or are you paying out of pocket?
As for the "plug blew out, injector was stuck open", one doesn't happen because of the other. Sounds more like the shop screwed up the insert install and blamed it on an injector. BS alarm is ringing...
RAMRODMUDDER, stuff happens. Was it covered under warranty? Or are you paying out of pocket?
As for the "plug blew out, injector was stuck open", one doesn't happen because of the other. Sounds more like the shop screwed up the insert install and blamed it on an injector. BS alarm is ringing...
Senior User
Joined: Oct 2007
Posts: 157
Likes: 0
Again, I must remind everyone who has NOT had a problem to VOTE in this poll to keep things somewhat realistic.
RAMRODMUDDER, stuff happens. Was it covered under warranty? Or are you paying out of pocket?
As for the "plug blew out, injector was stuck open", one doesn't happen because of the other. Sounds more like the shop screwed up the insert install and blamed it on an injector. BS alarm is ringing...
RAMRODMUDDER, stuff happens. Was it covered under warranty? Or are you paying out of pocket?
As for the "plug blew out, injector was stuck open", one doesn't happen because of the other. Sounds more like the shop screwed up the insert install and blamed it on an injector. BS alarm is ringing...
I'd really like to reply but it won't let me...."this post is closed" is printed at the bottom of the results. Has been that way for some time.
New User
Joined: Nov 2007
Posts: 10
Likes: 0
From: Northern NEW YORK
Krewat, i know stuff happens. Ford is Going to fix it cuz the injector caused everything and The 3V 5.4L head i got Do Not Have Any Inserts. How ever this happened i dont care it's getting fixed by ford and it sucks cuz i love the truck just hate the motor, oh well stuff happens