Spark plug blown out on 5.4 Ford

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Dabigguy

Pompous azz
Joined
Jun 1, 2005
Messages
3,028
Just a little heads up for you guys. I have a 1998 Expedition 130k miles that started ticking like it was an exhaust leak. Well, it wasn't a manifold leak, it was the spark plug backing out and ripped the threads out of the heads. It seems that it is a fairly common problem.

The dealer wants $3500 to do the job, but there is a tool by a company called Time-Sert. The tool's $500, but they say it's worth it's weight in gold!!! I found a guy that rented it to me and I will tackle that job tomorrow. Happy 4th !! I'll write back with the results.

FYI, if your 4.6, 5.4 or V-10 Ford starts ticking, check your plugs, it will save you lots of heartache.
 
You can buy the kit from atd for I believe $250 when it first came out it was like $800. I have done quite a few at work.v 10 vans. Then ford came up with the three valve motor so I had to buy the tools to remove the broken plugs on that pos
 
I would do some research. There MIGHT be a TSB out from Ford concerning this issue. (If there is it might be covered) I know on the 2001 Lightnings many owners has issues with them spitting out plugs.
 
Thanks Chopped, I looked at ADT, but didn't see the tool for '98. I have the tool in hand to do the job, I just need to get my butt out there and do it. :-)
 
It is semi common, normally caused by someone overtorquing the plugs. That dealer quoted you a head replacement. 95% of them can have a heli-coil put in them and be great. If you have questions, etc let me know.

Steve
 
Ford has been ducking this issue since the engine came out in '97. They said it wasn't even covered when they were new. There's stories that people with only 30k miles that had this problem and Ford would only cover part of the repair. It seems that there are only 5-6 threads in the alum. head that holds the plug. can you say design flaw?

They say it's only a 2 hour job, go I'll allow 4 hours for me !!!
 
It is semi common, normally caused by someone overtorquing the plugs. That dealer quoted you a head replacement. 95% of them can have a heli-coil put in them and be great. If you have questions, etc let me know.

Steve

Thanks Steve. Ford says DO NOT use Helicoils. They have a different expansion rate than the alum. head and will loosen and only last a short while.

It's a 13 hour job to R&R that head.
 
It seems that there are only 5-6 threads in the alum. head that holds the plug. can you say design flaw?

BINGO!!!

I've done more of these than I care to remember. Depending on which cylinder it is, they're not bad to do at all. Just make sure that you grease the end of the piece that you use to peen the insert over. It will make it much easier to remove it.
 
As stated there is very little aluminum grabbing those plugs on the Ford modular engines. Very common with plugs that have high mileage and/or under torqued to loosen, then they rock around in the cup till they do enough damage to blow out destroying the coil pack at the same time. If they are loosening up they will tick to give you some warning. I've found finger tight plugs many times on Ford trucks. There is no reason to spend big $ if it is a high mileage engine, Helicoil works fine. Run the tap, turn the engine over to blow out any metal, put the Helicoil on the new sparkplug, Red Locktite the coil threads and use the sparkplug as your tool to insert the Helicoil into the head. This way you set both at the same time. The last one I did has 40k on it, on a 240k mile F250. Even though Ford won't recommend this method because they don't make any money on it, its what many Ford dealers do.
 
time cert or lock n' stitch, l&s is ford approved... I did a few soild coils on my expy... Did not work as I hoped... I have some heads on order right now... Pretty cheap p&p'd better than risking the coil inserts... I did 3 that lasted over the fender but I prefer the security of the job done right... If you need details lmk.
 
There is a kit you can buy that contains the spark plug and adapter. Probably 40 bucks. We have used these at work a few times on 5.4's and the adapter is self tapping then you install the spark plug. It's that simple. I probably have a couple in one of my drawers. I will check in the morning. If so I will drop it in the mail to you free of charge. It's a fairly simple fix believe it or not. Shoot me a pm if you want it and I'll get it to you.
 
Yeah they sell the kit to repair the 'blown sparkplug problem' at local parts stores like Autozone and Advanced Auto for pretty cheap.
 
Forgot to mention earlier. You have the 4 thread heads. There are only 4 threads to hold the plugs. Even with certs they're still a very common problem.

To be done with it once and for all you need to swap over to the thread heads. These come off late 2003 5.4's. My new 8 threads are coming with steel certs as well for extra insurance...

That over the fender stuff does work but it seems as if it's only temporary... Just swapped the plugs on mine and ended up pushing the cert into the cylinder head:eek:
 
As stated fairly common I have seen it on the lincoln Mark 32 valves ads well as 2 V Mudstain GTs.

On the Lincoln the guy noticed it missing and didnt know the plug had backed out and thought " Im only 20 moles from the house its probably a bad sparkplug wire or something".

Unfortunately the inj was firing and the cylinder got washed out and took out the wrist pin:eek:.

1200 dollar lesson.

On the GT, guy just helicoil'd it and.......wammo back in business
 
I'm getting my new Windsor heads from these guys: Modularheadshop - MHS

I should have them next week. I'm going to swap them and do new timing chains. I can shoot a few pics and let you know how they work for me if you're interested...

BTW, the customer service is top notch.. Guy exchanged emails with me to cover all of my issues/questions even on the weekends!
 
The adaptor I'm talking about cuts entirely new threads despite how many threads you have left. This is truely the ticket and it's specifically for a 98 5.4 Exped.:wink:
 
Here you go. Go to any parts store that has a "help" section. It is a "help" brand part no. 42025. This comes with 1 new Autolite plug, new sparkplug boot and the adapter I spoke of. This should get you back on the road.:)
 
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