Car Problem Reports

Ford Excursion A Spark Plug Could Blow Out of Cylinder Head

Ford Excursion Problem
16 Reports
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Model Years Affected: 2000, 2001, 2002, 2003

Engines Affected: 5.4L V8, 6.8L V10

Average Mileage: 164,168 mi (125,000 mi - 232,354 mi)


There is a technical service bulletin for the V8 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug hole. If the vehicle is under warranty, cylinder head replacement is recommended. If the vehicle is out of warranty, Ford authorized the use of a specific thread insert to repair the head.

  • Visitor, , 6.8L V10, 125,000 mi

    Year 2003 also has the problem! I have a 2003 Excursion and I've had 4 spark plugs blown all different ones!
    BTW who cares what ford authorized!!! They should recall and fix their shitty crap!!!

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  • Visitor, , 6.8L V10, 194,000 mi

    TThe problem just happened. It's in the shop now to try an d fix.

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  • karnescj, , 5.4L V8, 156,000 mi

    the front cylinder blew out the spark plug and broke the mount for the coil pack.

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  • Visitor, , 6.8L V10, 125,000 mi

    I have the same blown spark plug problem and am currently searching for an answer!

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  • Visitor, , 5.4L V8, 232,354 mi

    Pulled out from getting gas and heard a loud pop. Took me a while to find that the #3 plug on the driverside blew out of the cylinder now I can't get a new pkug to thread in.

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  • Visitor, , 6.8L V10, 125,000 mi

    #3 spark plug blew out yesterday, classic case, had no clue this was a problem with Ford until I started googling yesterday, going to have to pay out the hiney to fix.

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  • Visitor, , 6.8L V10, 168,000 mi

    third time the plug has been fixed, its a different one each time.

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  • Visitor, , 6.8L V10, 170,000 mi

    I had 1 replaced about 10k ago and now another one blew out of the cylinder. repair tech said it has already had the thread repair on that cylinder. How??? I bought this vehicle brand new off the lot.......REALLY come on Ford what the cuss??

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  • Visitor, , 6.8L V10, 155,000 mi

    2 seperate occurrances of a single spark plug being ejected, starting around A-75,000 miles and a different plug, B-125,000 miles. This Excursion is not used for towing; It has a normal (easy?) duty cycle.
    After second ejection, all on the drivers side, all unaffected spark plugs holes were repaired anticapating additional, new failures. No apparant failures on the passenger side of V10. One blowout, A-75,000 miles, that was repaired, cylinder #9, appears to be failing again, possibly because the new spark plug was cross-threaded into the repaired cylinder head.

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  • Visitor, , 6.8L V10, 215,000 mi

    Suddenly blew out plug on way to work - no issues prior - been about 60K since last tuneup

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