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Old 09-26-2003, 12:18 PM
Junior Member
Join Date: Sep 2003
Vehicle: 1998 Ford f150
Posts: 3
5.4 Stripped Spark Plug hole

My brother in-law just stripped out the threads on one of the spark plugs holes.

Not so bad with cast iron, but, it's an F150 with a 5.4 liter, ALUMINUM heads....

His wife just had a kid, he's broke, and the dealership wants $3,500.00 to do it....

I'll pull the head. I do not know if aluminum can be re-threaded somehow... Helicoils ....

Please help, he's a hard working young guy and a great father and great kid....

If this can be done, does anyone know by who? We are in Massachusetts but are more than happy to ship the head elsewhere.....

Thank you
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Old 09-26-2003, 12:27 PM
Senior Member
Join Date: Aug 1999
Location: NC
Vehicle: 2005 Ford Expedition
Posts: 329
Try searching this forum for "blowout". I think I recently saw someone talking about a helicoil fix.

There are millions of these motors around. I'll bet you could find a scrap or reconditioned one way cheaper, and get someone else to install it for less too!!
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Old 09-26-2003, 12:34 PM
Junior Member
Join Date: Sep 2003
Vehicle: 1998 Ford f150
Posts: 3
He didn't strip it, it blew out!!!!!!!!!!!!!

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Old 09-26-2003, 02:38 PM
Senior Member
Join Date: Aug 2000
Location: Friendswood Texas
Vehicle: 2012 FORD F150
Posts: 1,629
living with ford spark plug blow out problem

look at this thread, in the second page they talk about a fix. i think it can be done with the head on the truck, check it out.
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Old 09-26-2003, 03:27 PM
Senior Member
Join Date: Jan 2002
Location: Oklahoma
Vehicle: 1999 Supercharged Ford F150
Posts: 2,248
go to www.timesert.com or call them at 800-423-4070

They sell a kit that allows a person to re-thread the hole and or can put stronger/more theads in the hole. They sell one for our specific trucks. No price on site, but I think the kit is around $100 bucks or less.

If your able to remove the damaged head and the re-threader is not an option, you could always just buy two salvaged/new heads for $500 or one head for less through, car-part.com or fordpartscheap.com, or fordpartsonline.com or ebaymotors.com I hate to see a working guys work transportion down like that. Keep us informed.

Good luck.
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Old 09-26-2003, 06:09 PM
Senior Member
Join Date: Sep 2002
Location: Austin, Tx.
Vehicle: 2002 Ford F-150
Posts: 108
Someone that works at O'reilly auto part recently posted that they now sell kits to repair the FORD threads. They are not helicoils, but much stronger. Also, partsonline.com sells complete new heads for $800. I've seen other advertisements for new heads around $400. Good luck.

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Old 09-26-2003, 06:29 PM
Senior Member
Join Date: Jun 2002
Vehicle: 2002 Ford F-150 5.4L
Posts: 4,205
Don't beat me up guys but you said it "blew out"?? Wouldn't this be covered by warranty or something?? Unless of course it's older.
'02 F150 XLT 4X4 SCrew. 5.4L

K&N FIPK/Amsoil Filter
Flowmaster 40 si/do Exhaust
305/70 16 GY MTR Kevlar
16X10 MB Motorsport wheels
4.10 Gears
Rancho 4" lift
Rancho 9000XL Pro Series Resi Shocks
FireStone Air Bags
Autometer Carbon Fiber Oil/Trans Temp Gauges
Carbon Fiber Interior (www.dash-kit.com)
Peterson Fluid Sys. Remote Oil Filter
Troyer Performance Electric Fans
Underdrive Pulleys
Amsoil Fluids Throughout
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Old 09-26-2003, 08:17 PM
Senior Member
Join Date: Jan 1999
Vehicle: "99" FORD F-150
Posts: 7,013

HI!... You need to pull the head and do like this. You will NEVER blow out a plug again with this set-up. Heli-coils have been proven to fail when installed in the 5.4 aluminum heads.

"1999" F-150 XLT SPORT, BUILT 5.4, all N/A.
354RWH.P/392RWTQ (no tune, yet) on 8 cylinders/ 1/8= 8.4, 13.60E.T (on 7 cylinders, broken ring in #5), 1.8 60FT.

"2007" FORD RANGER SPORT, EC, SB, 4X2, 4.0L. 1/8= 8.8, 13.83E.T
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Old 09-28-2003, 04:29 PM
Senior Member
Join Date: Oct 2000
Location: southington ct usa
Vehicle: 2001 Ford F-150
Posts: 598
E-mail me I have a kit that may fix it for you without removing the head. I'll send it to you for a small deposit, with a variety of inserts, just return what you don't need.
2001 F-150 XLT S-CAB 4.6

93 Kenne-Bell Supercharged Mustang
"Injection is nice, but I perfer being blown!"
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Old 09-28-2003, 04:29 PM


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