I found this thread because I'm about to buy a TimeSert 4412E kit from ProMar Engines to fix my '99 CV NPI 4.6L. I blew #6 out 1,000 miles into the 1,400 mile trip home after I bought it in Boston last weekend. I glued the plug back in the head with putty epoxy, unplugged the coil & injector, & drove the remaining 400 miles on 7. I've been driving it the past week occasionally, using my ScanGauge to keep TPS & Load under 60% so it doesn't blow out again.

 

ford designed the spark plug blowout as a fix for the problem of the major complaint of "spark plugs are hard to change" so ford fixed this with the 5.4 which will automatically remove all plugs from the engine when they are"designed" to come out.

 

FAST, YOU FOUND THE LEAK!! Yup , Fords hardball attempt to control the public Wynny's who don't properly maintain this awesome product. They **** and moan at the manufacturer about issues that arise due there own negligence. Fords not putting up with this Bull and I love it..200,000 on my 5.4L and don't let a set go past 50k.
A wake up call to those who abuse there vehicles. They all here about it, it has become amusing at FOMOCO and Visteon as well.

 

Ford fixed the problem with their 04 3V tritons. The SOB's won't come out now.

JMC

 

I will not go into much detail about my cross country move after 9/11 from AZ to NJ in a U-Haul that has the Ford 5.4L. I blew out going up the huge hill outside of Albuquerque on I-40. Boy did that add extra days to my trip. UGLY! In any case, it is good to hear that Ford has resolved the issue. I just bought an 06 F150 5.4 and look forward do many year of good use......

 

I was being sarcastic. The F'ing plugs now break off inside the head. Ford has a TSB on how to get them out.

JMC

 

LOL sarcastic but true, I'm starting to see that Rotunda extracter on eBay now lol. They should put one in the glovebox along with manual when purchased new.

 

or a small acetelyn torche lol

 

Yeah , lol , some JB Weld and an extra plug to go with.

Call it the XLTnT package.

 

if you want some help i could do yours for you for a small price hows half the price of the kit sound so 200 dollars sure does beat 3000 for them to replace the head that could do the same thing again

 

I joined the club about two weeks ago.
About half way between Las Vegas and Mesquite Nevada. We were on our way back to Utah from a Disneyland Vacation in our ’98 Expedition with just over 80,000 and Bam tah tah tah. At first I thought it was something with the exhaust manifold. I had never worked on the engine and so I hadn’t read any forums related to the Expedition or Tritons. After we pulled over I started the engine again and found there was air blowing out from the area where the noise was (along with the smell of gas). I thought, “this isn’t good” especially since we were at least 30 miles from anything. Then I saw the broken COP. #3 out from the firewall on the passenger side. I usually bring a small tool box on trips so I was able to remove the COP and the plug that was just sitting in the spark plug hole. I figured it just came loose. I will just screw it back in and re-attach the COP and we’ll be on our way. Ya right. Well my 3” extension wasn’t enough to screw the plug back in but I was able to kind of get it started (or stuck) with a screwdriver in the end of the extension. I disconnected the injector, and put the COP back in place (without connecting it). It wasn’t working but at least it wasn’t so loud and wasn’t blowing air.

We were able to drive to Mesquite where I stopped at AutoZone looking for extension, new spark plug and possibly a “thread fixer”. I knew I was in trouble when a customer at the counter said “You’re screwed, those engines are known for throwing plugs.” What? I hadn’t heard anything…
Well after about 2 hours of trying to get the new (and old) plug to stay in I figured we had to try running without the plug. We only had about 300 miles to goL. It sounded like a steam engine. The kids asked “Is it going to blow up?” My reply was “I don’t think so”. The funny thing was it ran best about 70 mph (less vibration) and we got better gas mileage than on the way out. It didn’t like the hills much but all in all it wasn’t too bad. When we stopped for gas the guy asked if we were ok. When I told him what happened, he said “I heard that’s common with those engines.” What???

After arriving home I jumped on the internet and to my surprise blown plugs are over the place… “Dropping like flies” comes to mind.

I decided to purchase the Timesert 5553 kit and 3 extra inserts so I could do all of the plugs. I started with the passenger side. #3 out from the firewall. It went pretty smooth. The instructions were pretty clear and the video on the net helped (It would have been a piece of cake on a bench like the video). It took about 2 hours to get all the junk out of the way on the passengers side. The fix took about another 2 hours. Shavings in the cylinder was a constant worry. After #3 was done I decided to do #2 and use that as an indication as to whether I would be able to do #1 (closest to the firewall). #2 also took about 2 hours, but it was clear that #1 would be a problem. With #2 you’re right on the edge of the firewall/cowl area. With #1 your under the cowl and there is a metal coolant tube right in the way, the only way I can see to do it is to get the tool tip (reamer/threader/expander) in the hole and then put the other piece on top. Since you are constantly removing the tool to clean and re-grease it this would be a real pain. Not to mention you cant even see the hole. At this point I decided to only do the inside plugs (2-3-6-7). I read in the forums that most of the time it’s the inside plugs that pop. The decision to not do all of the plugs hurt financially. I was going to try and sell the 5553 kit on ebay after the fix was complete but now I will have to keep it.

Next I pulled all the junk off the divers side. Again that took about 2 hours (more tubes, less electrical). When I pulled the plugs, #7 (2 from the firewall) was not tight (I still had to use a ratchet, but no torque). I did that one next. Since it was under the EGR tube I had to use the Timesert tools with a universal joint (a wobble extension would probably have worked). Then I did #6. It was easiest so far but it still took 1.5 hours with all the chip/grease removal and the vacuuming and blowing with compressed air. I read somewhere that a guy said he could do the whole fix in 35-40 minutes??? I would like to see it. You would be my hero. I torqued the new plug to 13ft-lbs (156 in-lbs). That sure doesn’t seem like very much. It took about 2 hours to put everything back (not counting the time I spent looking for a dropped socket). This morning I started it up and it started right away and runs smooth. I don’t believe I could have gotten all of the chips out so they must just get blown out in to the exhaust.

Since its done I can say it wasn’t that bad, but if that were truly the case I would have done all 8. I just wish the 5553 kit wasn’t so pricey. It cost me $374.80 + 3@10.21 plus shipping. Granted it is a lot less that replacing the head.

 

Check out the below link on plug blow outs -

http://www.consumeraffairs.com/news0...on_lineup.html

 

We have about 50 E350 vans at work with the 5.4 All with around 100,000 miles on them.

Last week one of the drivers reported a thud sound and the smell of gas. On inspection it was a blown plug.

 

Hey Blademan,

My sons 2000 Expy just joined the club of a blown out plug. We are very local and want to know if you are still willing to help us out. It is at our local mechanics shop right now and will find out more info tomorrow morning.

 

or you can change em every 100,000 miles like they are dessigned to last.... just like every other engine that doesn't blow out plugs.
quit making excuses.