Well...I found a truck shop that will do a helicoil with the head on...they have not seen the truck yet, but said they have done it before. I have to wait until next Wednesday to have it done though. They said a couple hundred. Any advice to keep in mind?
I am concerned about crap getting down the plug hole.

I was thinking of having them replace all the plugs while they were at it...opinions on this welcome...I have 55k on original plugs and don't want to F##k with them again. I am also worried that maybe another one can fly out. I bought the truck with 37k on it and doubt the plugs had ever been touched.

If helicoil fails...what is reasonable charge for head replacement...

 

Give JLP a call . He fixed my head with a metal sleeve. Works great with 0 problems. Hope this helps

 

perfect timing for this thread. Last night the #6 plug shot out, took a look at it this morning and the coil pack is damaged, the sparkplug is still in the coil pack but is just dangling, the threads don't appear to be stripped though.

 

I had a plug blow in mine 2 months after I got it. It was the 3rd back on the passenger side.

 

brap...when I had mine replaced, the mechanic told me the threads were ok too...well they weren't. Logically, I don't think the plug could blow out and not take some/most of the threads with it. my guy screwed it back in and it is still in there, but I am losing compression out of that cylinder...better prepare yourself.

I am driving a rental because I don't want to blow the coil pack again before I can get it fixed...then I have to decide whether to keep the truck or not. Good luck with yours...after I had my new coil pack, I experienced a very rough idle when in gear...tat was the compression leak, but my CE light did not come back on for 2 weeks. Pay attention to the symptoms.

 

Dose the ticking happen at all RPM's and MPH or dose it only tick at certin times? Mind makes a ticking but almost like a rattling noise on the driver side when crusing at 35-45 MPH or when giving it gas at thoses speeds it will make the noise. Is this a spark plug about to blow or what? I even had it at the dealer but they don't know what it is.

 

mjcar,
Do not get a helicoil put in with the head on the block. They have to re-tap the hole, install the coil, then plug. At the very least your cylinder will be full of aluminum shavings from the tap. Even if they vacume it out. It's just way to risky.

 

Add me to your list, here is my sad, sad story.... P.S. I used to tell everybody how I loved my ford truck....

I took my 1998 ford E350 van into ford dealer for repair ($1700). One of the spark plugs poped out of the cylinder head (drivers side 3rd back) taking all the threads with it. The service manager said that this happens once in a while. They pulled the head off and sent it to a machine shop where they will install a insert. When I asked him what about the other 7 plugs, will they hold ? He just shrugged his sholders.The van e350 5.4L has 122,000 miles on it, the plugs were changed by a ford dealer at 90,000 . I have been searching for info on how many times this happens, I am starting to suspect that the plugs work their way loose due to engine vibration and the fact that the spark plugs only has 6 threads on it.
I want to explain why I suspect plugs working their way loose. After the new plugs were installed by the dealer the van ran fine ( it ran fine before the plugs were changed . ) 1 year and 25k miles later when the engine is idling I hear one loud tap head sound , It was pretty loud and kinda what you would expect to hear from a old chevy motor. The van was still running great so I looked at the milage (115,000) and figured this motor deserves to have a loud tap head - I'm not going to mess with it. 5k miles later the plug blew out when I started it one morning. by the way, when the plug blew I didn't have a clue what was wrong, I thought a emission sensor on the exaust manifold broke off. I drove the van to a ford dealer and the van ran fine ( except for the loud exaust sound) , I still had no clue the van was only running on 7 cylinders. After the van was repaired I noticed there was no loud tap head sound anymore. So I think one plug worked loose over time.( the loud tap head sound was the plug banging up and down in the threads ) with the plug loose it's very easy to understand how it could blow out taking the threads with it, as the pistion sucks and exausts the loose plug would be like a jack hammer against the threads and it wouldn't be long before that plug would distroy the threads.
The thing I blame Ford for , is designing a van that is just about impossible for a average Ford trained mechanic to change the spark plugs correctly and the spark plug they use only has 6 threads on it so it has to be installed perfectly, and even then it still might loosen up at any time.
Anyone want to email me direct--> donswr@hotmail.com

IF YOU HEAR A LOUD TAP HEAD SOUND COMING FROM YOUR ENGINE WHEN IT'S IDLING... DON'T IGNORE IT !!

 

If I had a truck or van with that much milage on it I would just go for a new long block for $2,900 rather than pouring good money into a bad cylinder head.

New 5.4 Long Block

 

I agree with you now that I am thinking clearly, but at the time I was kinda in shock and the service manager didn't even hint about changing the engine. If I had to do it again I would go for a rebuilt engine. I know it would be easier to sell .

I guess the mileage looks like alot to you, I am a delivery man and have been driving ford E350 vans for 20 years. I expect to get at least 200,000 miles out of it and the sell it in good running condition to someone else. If I expected to get only 100,000 miles I would buy a chevy.

 

ok number 3 blew on my 01 L and the #7 melted a plug..

 

Sorry to hear that. Would you post details, i.e., mods, what way were you driving when it happened, gas used, etc.?

Dan

 

Add me to the list, lost my # 6 plug yesterday. I have about had it with Ford Quality. I have a bone stock 2000 L that has had way too many problems.

 

second one back, pasanger side. No warning. Just cruzin at 65. 01 at 19,000 miles.No mods. Being replaced with new but same design head , even though a new head with more threads exists.
phooey!

 

This is news to me.....Great news! It's 'bout time for this