Thanks SteveB.

I was thinking about doing that, but I didn't think I could get it to reach easily because of the rear heat on the Expys. I ended up going to the dealer to get a replacment clip kit for $8. I am thinking of replacing the heater hoses with just standard hose and clamps though. That way I could probably re-route them away from over top of the engine. Maybe those hoses might have a little to do with the #3 and #4 plugs getting corroded as some people report. Also, those hoses were sooo difficult to get loose in the first place. Quick connect fitting....yeah right. If you can get to them.

RedExpy

It's a 5.4 that I bought a year ago with 99 k on it. I blew the plug at 112 k. The plug that came out appears to be original. I've got 7 more Bosch Platinum 2 going in this weekend. I don't hear the 'lifter' or exhaust leak noise anymore. The plug that blew out didn't have anything unusual about it. No corrosion. Only thing was a hint of aluminum powder on the threads.

I've only got a few hundred miles since the repair. I carry the Big Sert kit with me along with an extra insert. It took me a week or so to get the kit the last time, so if I'm away from home I don't want to be stuck waiting.

Of course, I'm going to try to prevent any further ejections with appropriate maintenence.

 

Gents,

What is Ford's objection to Inserts? Does the aluminium just not hold?

Thanks for taking the time to answer.

Seth

 

Your looking at $3500 for Ford to fix the #3 by putting it back in with elmers glue?

Hell, I would just get some superglue and put it back in myself...

 

Sorry, I see that Inserts are being used for this. The $3500 is what Ford wants to put a new head on.

 

hmm, that sounds like 2 new heads. I think I was quoted about $1700 for one head.

 

Hello out there. does anybody here know if the 4.2 v6 is blowing out plugs?

 

The V-6 engine does not seem to have this problem although it is has known head gasket failures. This spark plug problem is associated with the newer overhead cam V-8 and V-10 engines. It would appear that Ford redesigned the heads on these engines for 2003 (quietly) and it's possible that these engines will not experience this particular problem. In the meantime, Ford is consumed with buy-backs on the 6.0 PSD engine. They could get consumed eventually with buy-backs on these 1997-2002 V-8/V-10 engines too. I think if my 1999 5.4 blows a factory-installed plug out and Ford doesn't care to worry about it - I'll sue. That's the way the 6.0 PSD owners got Ford's attention. Kind of a shame, really. I hate lawyers, but I also hate manufacturing defects that are not recognized and corrected.

 

I have an E150 with a blown #3 which, I believe, means I have to pull the head to put in a sert. If the threads are still sort of there has anyone ever tried LockTite or JB Weld to hold the plug in place? What is the risk of trying this? Maybe I could put the big repair off for a while?

 

Why has no one filed a class action lawsuit? It's seems like it's quite a common problem with the 5.4, and I can tell you right now if I had known this a couple of days ago, I wouldn't have purchased the truck I just did. It's actually quite scary knowing that at any random moment in time it might eject a plug. I have several pre-paid legal hours saved up, looks like I'll be able to put them to good use if/when my plug ejects.

 

Use the big sert they work great and you dont have to pull the head off to install, before trading in my 97 for a 04 I had #4 plug blow out. Used the big sert and had over 15k miles on it at trade in no problems saved the $3k and was able to still purchasse a new truck. If i had replaced the head I couldn't of been able to ordder the new truck. Eazy to install and worked great. The truck had 127k miles on it when the plug blew.

 

Here is a email I received on this subject:


Sent: Tuesday, January 27, 2004 1:16 AM
Subject: 5.5L BigSerts



Just wanted to pass along my experience, and my thanks.

My neighbor brought home a '97 Expedition this past weekend that
had blown out the #7 plug. When it blew, they had taken it to a
shop, who wanted to pull the head, and possibly more. The spark
plug looked like something had gotten into the cylinder and
hammered it out. It was really beat up. I did some searching,
and came across your post on F150 Online. Today we pulled the
rest of the plugs, which all were OK. Once we had all the hoses
and lines out of the way, I was able to shine a light down the
#7 spark plug hole, and was able to see that the top of the
piston still had a nice even coat of carbon. Definitely nothing
rattled around in there, so this was just another case of the
5.4 plug blowout problem. We got one of the BigSert kits from a
local supplier, and I can say I am very impressed with the kit.
Very high quality tools, and the finished result is as good as
I could have hoped for. First class. Better than new. If I had
one of these engines apart, I would definitely install the inserts
in every hole as a preventive measure. The kit cost $120, plus
$7.50 for the insert. Worth every penny.
A day's work, a set of Motorcraft Platinums, and a new coil (ouch)
and we're back in business.

One note- in your post, you say that the insert is locked into
place when you install the spark plug. Actually, the kit comes
with a tool that does this. Once complete, the spark plug is
installed and torqued as if nothing had happened.

BTW, I did the shop-vac blowing into the tailpipe trick. Slick.
I also have a small vacuum cleaner that has a long skinny tube
attachment. I was able to stick this tube down into the cylinder
before I installed the insert.

Thanks Again!

 

98 Expedition 72,804 miles POW!

I called Ford based on the messages here and they said if enough people call they might actually do something about it. She said to hold on to receipts of work in case they admit to the problem. This is going to happen more and more as these vehicles age.

I also have a warranty that will not cover this. I bought it for peace of mind but in actuality it is a piece of crap. The cost of the warranty would have almost covered the damages.

CALL FORD AND COMPLAIN!!!!

I will try the steel threads.

Good luck to all and don't frigen buy these pieces of crap.

 

Hi All,

>Good luck to all and don't frigen buy these pieces of crap.<

I was in the market for a used F150. I have wanted to purchase one for a long time and finally saved up the money and started my Internet research.

I forgave the crash results, the head gasket problems and almost the spark plug problem but this thread really sunk in. I just happened to be at social where I had a brief conversation with a Ford service advisor. I asked him about the spark plug problem. I was fully expecting he would not even acknowledge the problem, I was way off. He said the problem is a nightmare and sees it all the time. He would not say much else except that they have not had a problem with the 04’s.

I feel for all those of have this problem. I am not sure how Ford would have let this go out. This is a poor design and they should have corrected long before 04. I am sure they looked into some sort of recall but it would just be too expensive for them.

04’s are too rich for my blood so will have to look at Chevy (like a knock) or Dodge (transmission). Sure they all have a problem but a blown spark plug means you are dead in the water. So when you’re fully packed some dark night, camper in tow, trying to reach the campground, I know that is when mine would go.

I did not let Ford down, they let us all down. Anyone have any good web sites for Chevy or Dodge trucks?


Bob

 

Hey beomanj was your warranty threw Ford or an after market?

John

 

just wanted to say thanks for all the great information in this thread. #2 went out on me a couple weeks ago @ 73k miles. Had it towed to the local Ford dealer and went home. I immediately came here to see if anyone else had experienced the spark plug problem. So, obviously I knew what the service rep was gonna say b4 he even called. "$3500.00". I just laughed, ordered up the big sert kit and had a mechanic friend put it in. Total cost with kit & labor: $500.00.

Thanks again and good luck to all of us, we need it.

*waits for #3 & #4*