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.
Car Problem Reports
Ford F-250 Super Duty TSB For Possible Ejection of Spark Plug From Cylinder Head
Ford F-250 Super Duty Problem
Engines Affected: 5.4L V8, 6.8L V10, V8
Average Mileage: 125,714 mi (51,000 mi - 185,200 mi)
Visitor, 1999 Ford F-250 Super Duty, 5.4L V8, 110,654 mi
plug blow out,
Visitor, 2002 Ford F-250 Super Duty, 5.4L V8, 113,000 mi
spark plug blew out
Visitor, 2000 Ford F-250 Super Duty, 6.8L V10, 115,000 mi
front plug on the passenger side of the engine. Fixed by the guys at blownoutsparkplug.com. 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.
Visitor, 2003 Ford F-250 Super Duty, 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
Visitor, 2002 Ford F-250 Super Duty, 5.4L V8, 110,000 mi
#6 sparkplug blown out. Not yet repaired.
#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
# Four Plug blew out . I have not had it fixed yet as of 10/15 /11.
Visitor, 2002 Ford F-250 Super Duty, 5.4L V8, 51,000 mi
Had to pay Sonora dealer 5,000 to fix. they told me it was NOT covered by waranty
I just had the second one blow out withing ten months both on the pas side.
Visitor, 2001 Ford F-250 Super Duty, 5.4L V8, 120,000 mi
Blown spark plug, took out coil pack also. Ford replaced spark plug used heli coil and new coil for a cost of $300 plus dollars.