OMG! It looks like a bomb hit it.

Have you found a way to fix it? I'm almost 100% certain that Ford does not advise any kind of fix other than to install a new head.

 

I think I'll be getting a new head after taking this thing apart anyway. I'm afraid I'll be doing the same thing the next time if I just try to rethread the hole. I figure it will just leave weak threads....I don't want to have to do this again anytime soon.

 

Hey 88,
I just picked up a factory service manual on CD, and they cover this. There is a tool (set, kit, whatever) to fix this. I'm not totally sure it's for your truck (it's a '98 manual) but it could be an option.
You have to take the head off to retap, but if it works it would be far less expensive.
Any one else familiar with this? I could look into it further if necessary.

Tom

 

These guys know what they are saying on the helicoil...I work in a garage and watches a mechanic insert a thread last week in an aluminum head...It works and appears to be long lasting!!!

 

How about finding a spark plug with the same depth but slightly larger thread diameter and tapping the head for the new plug when you have it off if the helicoil doesn't work.

Otherwise, take it to an aircraft welding/machine shop. They can probably weld the original spark plug hole nearly closed and retap it with the original size spark plug hole.

Matter of fact, in the latest issue of VW Trends there is an article on VW Type 4 cylinder heads where they are cracked around the valve seats and the guy drills a huge hole right into the crack and fill welds the whole thing, then shapes the cylinder head back to original shape in the machine shop. Incredible repair.

Just a thought. Sorry to hear of your motor blues. Good luck.

Edit: Hmmm.... you could always throw some 2001 Mustang GT heads on there.

 

As attached. You may have to open it in Photoshop and zoom in to read it but it is readable. Sorry for the low res... had to get it under 100k in size.... darn limits.

 

As attached.

 

Hey, did you guys/girls know that you can't post replies or threads within 60 seconds of one another.... weird rule.... doh.

 

I'm researching the idea of the 4.6 head. I read in Muscle Mustangs that putting 99 heads on a 96-98 increases compression and that the ports are square, not tear shaped as in mine. If I can use the stang head....they should have the same part # as the 5.4. So I'll call Ford in the morning and see about the idea. Thanx everyone for your help, keep the info flowing!!

 

The 5.4 intake will not work on a 4.6, regardless of the heads you use. The deck hight of a 5.4 is greater than the 4.6 so it is taller requireing a wider head.

Regards

Jean Marc Chartier

 

RATS!!! So close....yet still so far $$$$$$. Thanx though.

 

If the mustang heads did fit you could throw some mustang shorty equal-length headers on there for good measure.

Let us know what you do find out from Ford.

Would be nice with a set of higher flowing heads!

Thought about the aluminum welding solution any?

I suppose there's no problem with putting mustang heads on the triton 4.6 though right?

 

According to JMC the 4.6 won't work. If I knew how to weld....I might try that technique...but I really don't have the time to mess with it. I travel for work....I'm working in Connecticut, but I got the truck back home. My point being, I need to get the truck on the road asap. My co-worker used to be a mechanic for Chevy, despite his affection for Ford, and he frowns on the helicoil. Don't know...seems like the best thing to do is swap the head...but that's gonna suck $$$$$.

 

I didn't say weld it yourself!! I'd let my buddy do it for me, he works on magnesium and other exotic metals with aircraft and helicopters, etc. This guy can weld anything, but then again where he works it's for $50/hr. You see, they'd rather fix a $50,000 exhaust collector from the turbine in a helicopter for a few thousand than buy a new one!

If you're pressed for time get a replacement head, slap it on. Then when you have the time get your broken head welded up (just a 1/8" bead around the plug threads and re-tap it. You have to be absolutely sure of the person doing the welding to use the correct weld rod type (many different kinds of aluminum). Sell it as a used head after you fix it or keep it as a spare?

Those Mustang 4.6L 99'+ heads sound like the ticket... increased Mustang GT horsepower from 98 models from something like 225 to 260hp.

What sort of heads do they use on the 5.4L motors from Roush, Steeda, and the other hipo custom shops? Are these over-bored 4.6L motors or 5.4 modified?

Ahhh flock it... shoehorn a V-10 in there! LOL.

Ever wonder why Ford didn't design these heads with much longer plug threads? Would be cheap insurance. We'll never know. Probably the same engineer who signed of on the exhaust T.

Let us know how it goes.

 

Well here's what I found out about the 4.6 vs 5.4 head swap. The difference between the two motors is the length of the stroke. Bore is the same. Also, Ford used the same heads on both motors prior to 99. There is info on the SHM website that states you can even use the 4V cobra heads...but I don't have the time, nor need to pursue this route. It would be kinda cool though. Thanx to all for your help...and I'll continue to update this post as I get the truck fixed.http://www.seanhylandmotorsport.com/modsquad2.html