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.Google+
Car Problem Reports
Ford Excursion A Spark Plug Could Blow Out of Cylinder Head
Ford Excursion Problem
Engines Affected: 5.4L V8, 6.8L V10
Average Mileage: 167,181 mi (125,000 mi - 232,354 mi)
Visitor, 2000 Ford Excursion, 6.8L V10, 194,000 mi
TThe problem just happened. It's in the shop now to try an d fix.
the front cylinder blew out the spark plug and broke the mount for the coil pack.
Visitor, 2000 Ford Excursion, 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.
Visitor, 2003 Ford Excursion, 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!
Visitor, 2000 Ford Excursion, 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.
Visitor, 2000 Ford Excursion, 6.8L V10, 168,000 mi
third time the plug has been fixed, its a different one each time.
Visitor, 2000 Ford Excursion, 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??
Visitor, 2000 Ford Excursion, 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.
Visitor, 2001 Ford Excursion, 6.8L V10, 215,000 mi
Suddenly blew out plug on way to work - no issues prior - been about 60K since last tuneup
Visitor, 2000 Ford Excursion, 6.8L V10, 180,000 mi
My husband was setting with idle and all of a sudden he heard loud popping noise. Ywp it was the sparkler blown out and stripped the threads. Havent had it fixed, is it covered under warrenty??/ HMMM wonder