Car Problem Reports

Ford F-250 Super Duty TSB For Possible Ejection of Spark Plug From Cylinder Head

Ford F-250 Super Duty Problem
22 Reports
Me Too

Model Years Affected: 1999, 2000, 2001, 2002, 2003, 2004

Engines Affected: 5.4L V8, 6.8L V10, V8

Average Mileage: 126,996 mi (51,000 mi - 185,200 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.

  • BlackCloud, , 6.8L V10, 185,200 mi

    # Four Plug blew out . I have not had it fixed yet as of 10/15 /11.

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  • Visitor, , 5.4L V8, 148,100 mi

    Just today 12/15/13 driving 30 MPH. It is the first cylinder on the passenger side. #? I've read this is a extremly common problem, and I don't have the funds for repair. No longer a Ford enthuiast. Brian

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  • Visitor, , 5.4L V8, 110,654 mi

    plug blow out,

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  • Visitor, , 5.4L V8, 113,000 mi

    spark plug blew out

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  • Visitor, , 6.8L V10, 115,000 mi

    front plug on the passenger side of the engine. Fixed by the guys at They did a great job and are very knowleagable of this problem. They changed all the spark plugs with new ones and checked all the other cylinders for potential problems. Have not had any problems since.

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  • Visitor, , 5.4L V8

    Started my vehicle today, 12/15/2012, at the mall and..boom!! then some smell of smoke inside the vehicle ...then more popping which sounded almost like a belt slapping against something under the hood. I had no prior indication of a problem except yesterday morning there was a vibration in the steering wheel while accelerating that stopped once letting off the gas. It did smooth out within 45-60 seconds and did not reoccur. Then today's issue occurred. I had the truck, F-250, 2003 Quad Cab, with 150-K miles towed to the Ford dealership about a mile away which was the place of original purchase. Initial estimate to repair it..$700.00; not a happy christmas gift

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  • Visitor, , 5.4L V8, 110,000 mi

    #6 sparkplug blown out. Not yet repaired.

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  • TowerAuto, , 5.4L V8, 163,000 mi

    #5 blew out, it also destroyed the ignition coil
    The best repair is to remove both heads and have a machine shop install new inserts
    I have heard (but not seen) that some of the inserts installed with the engine still assembled have failed, this is most likely due to lack of room and access in the engine compartment

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  • Visitor, , 5.4L V8, 51,000 mi

    Had to pay Sonora dealer 5,000 to fix. they told me it was NOT covered by waranty

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  •  Rookie

    I just had the second one blow out withing ten months both on the pas side.

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