Ford Blown Out Spark Plug

[TeamAllen]

My friend has a Ford truck that has a spark plug that has blown out of the cylinder head. I know, I know, friends don't let friends drive Ford's, but that's the way it is.

He discovered it is very common for this to happen on most all 1990 to 2003
Ford 4.6L, 5.4L, and 6.8L engines in Mustangs, Trucks and Motor Homes. I have never heard of this happening, ever. He was quoted over $3,000 to have the work done. Outrageous, I know. He asked around and was told of a company fairly close to us that will repair them for around $650. He is stoked and I thought I would share the info he found for all you Ford owners and friends of Ford Owners. There is good information in the FAQ section to help check for and prevent it from happening.

http://www.blownoutsparkplug.com/

[laserfish]

Happened on my sons 99, and he was in the boonies on a deer lease at the time. Fortunatly, he learned how to work on cars early, disconnected the coil on plug and fuel injector, and drove it home. Very loud. We have heard about it shooting the plug through the hood when it first lets go!!! Ford in their cheapness only has 3 threads holding in the plug. Bought a Big-sert kit from time-sert www.timesert.com to repair. There have been enough for them to market a repair kit for this. Should have been a recall. Anyway, the kit was 350.00 or so dollars, an includes 6 inserts. Took a couple of hours, but we wanted to make sure everything was right. That was about a year and a half ago, and have not had any more problems. Not that tough to do, if you are mechanically inclined at all. Excellent directions included, and on the web site. Check it out, and good luck.

[TeamAllen]

Thanks Laserfish! I'll pass it along to my friend.

Your son did the right thing by disconnecting the coil and injector. If I had one of these problem engines, I would carry one of the Emergency Plug Kits with me.

http://www.blownoutsparkplug.com/Plugkit.htm

[laserfish]

I think I may purchase one for the tool bag, sure would make the trip home quieter if it ever happened again. Thanks for the link.

[dogbert]

Hmm, I've never had this problem with any of my Fords.

[laserfish]

Neither had I until I checked it out online. Google is a wonderful tool. As dangerous as the problem is, I am surprised it was not a recall. I guess it would have been too expensive to be replacing that many heads.

[chpthril]

Although there may not be a recall, check with your dealer to see if this would be covered under a TSB that would extend the warranty coverage for this failure

[anhaney]

Although there may not be a recall, check with your dealer to see if this would be covered under a TSB that would extend the warranty coverage for this failure

Guys this is a very common problem with FORDS. My company builds and hold the patents on the only tool that you can buy to get the plug shell out with. When ever you change plugs on FORDS the only chance you have to avoid costly time consuming repairs is to pull the coils. Spray a whole bunch of penetrating oil down the spark plug tube with the engine COLD and let it sit for 15-30 minutes. This will break up the corrosion around the shell and allow it to be remove properly if you are lucky. If not let me know and I will get you all the removal tool part number and tell you where you can buy it.

Then when you do get the plug shell out put in some good plugs. Ever since Federal Mogul bought champion from Cooper Automotive they have fixed there plug line and hands down build the best plug in the industry. There shells are all coated with ZINC or Anti Seize right from the start not to mention a ton of other designs. NGK is the next closest competitor.

GOOD LUCK another one of the wonderfull FORD engineering feets.

[laserfish]

anhaney, I knew we could count on your knowledge, I appreciate the input. After putting inserts into #2 and 7, I hope I don't have to do this again. Glad to know about Champion, but we put in a full set of motorcraft, so hopefully with 85000 on the odometer, we won't have to go through this again. The one thing that is a common thread for prevention is changing the plugs COLD. I guess the coefficient of expansion of the aluminum head and steel of the plug makes for an important difference.

[TeamAllen]

This is the only TSB I know of.
It is highlighted to show there is no warranty associated with this repair.

http://www.blownoutsparkplug.com/images/tsb07-15-2.pdf

[TeamAllen]

Hmm, I've never had this problem with any of my Fords.

That's why I brought it up. Just giving some a heads up. I hope you or anyone else never has this problem. It sounds like a major pain.

[anhaney]

anhaney, I knew we could count on your knowledge, I appreciate the input. After putting inserts into #2 and 7, I hope I don't have to do this again. Glad to know about Champion, but we put in a full set of motorcraft, so hopefully with 85000 on the odometer, we won't have to go through this again. The one thing that is a common thread for prevention is changing the plugs COLD. I guess the coefficient of expansion of the aluminum head and steel of the plug makes for an important difference.

Man if I were you I would pull them out while I could and get a good set of Champions in there. NGK does not have ZINC in bedded into the shell. MOTORCARP has hard steel and the threads are cut threads on the plug rather than rolled threads like champion. In addition to that the way the core is put together your sure to have the same problem sooner or later. I would hate to be stuck on the side of the interstate with my boat attached and have one go out on me. That would really suck.

Wait that did happen to the person who was delivering it to us after we bought it. It sat at the state line of Nevada and California for 8 hours disconnected from the vehicle so they could limp the truck back to Vegas for repairs. One person stayed in the boat with no gun, Cell phone, or any kind of communication while the other went back to Vegas for repairs. And I was stressed wondering if I needed to run over and pick it up before someone else picked it up at no charge.

[dogbert]

Ok, so my current 2004 F-150 has 100K plugs in it, do I need to worry or did they finally fix it?

[TeamAllen]

According to their website you should be OK.

Q: Have the threads in the newer engines been upgraded?
A: Yes. most all 1990 to 2003 4.6L, 5.4L, 6.8L engines used the 4-5 thread design cylinder head. In 2003 the SOHC 2 valve type engines were upgraded to a 9-12 thread spark plug design. The newer 3 valve type engines use a whole new type of sleeved spark plug.

[dogbert]

I think I have platinum plugs in mine.