Has anyone heard of the cylinder head absorbing oil into the spark plugs? My mechanic tells me this has been noted on Windsor 4.6 Engines. Apparently, when the heads were cast, the aluminum was pourous (had air in it), and this causes oil to absorb into the head and foul plugs. I know this sounds crazy, and is almost hard to beleive, that's why I'm hoping someone has heard of this before. I only have 40 days left on the warranty and would realy like for them to pay for this one.

 

The correct terminology for this condition is porosity. The oil will migrate thru the metal via the pores in the metal. Aluminum is more prone to this than cast iron but is not unheard of in cast engines. Ford is aware of the problem, your dealer may not be. Best of luck.