One or More Spark Plugs May be Ejectioned From the Cylinder Head on Ford F-250 Super Duty

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.

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Average mileage: 129,612 (51,000–200,000)
Engines affected: 5.4L V8, 6.8L V10, V8
6 model years affected: 1999, 2000, 2001, 2002, more2003, 2004
35 people reported this problem
22 people shared problem details
2002 Ford F-250 Super Duty- 5.4L V8148,100
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
The Spurk on engine v10 shoot out and lost power...the attached plastic cable broken with the bang... It just happened after I stop in a sign stop and moved... It sound like bang... And the engines kept running but making loud bang... No power to drive. My cost to repair was is $200 plus I had to pay towing. The car has been own by me for two years.
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
# Four Plug blew out . I have not had it fixed yet as of 10/15 /11.
2003 Ford F-250 Super Duty- 5.4L V858,000
I put the insert in w/plug and new coil pack. After replacing 3 other ones, the first replacement blew out!! I now have to replace the head on a 2003 with 61,000 miles!!!!
2001 Ford F-250 Super Duty- 5.4L V8110,000
spark plug ejected out of cylinder head at approximately a hundred ten thousand miles mechanic told me second time this is happened to same cylinder I had to order special tool from California will not be able to fix next time also said on any Ford made out of a certain plant this is a common problem could be in a Mustang and a truck etc
1999 Ford F-250 Super Duty- 5.4L V8164,000
Second time a plug blew out. Not sure of the expense yet. Slept in the van on the highway. Diagnosing it now.
Cylinder head number 6 popped out. Local shop used lock tight glue to get new plug back in.
2000 Ford F-250 Super Duty- 6.8L V1070,000
Happened twice, one at around 70,000 miles, again recently at 90,000.
1999 Ford F-250 Super Duty- 6.8L V10152,550
Two plugs blow out on the passenger side within a year and now I feel like its happeneing again. Same kinda before symptoms. But me and my dad replaced both with a helia coil ( however you spell it) I think there was one other part but ordered from Napa amd was only 75 bucks or so. The first one was a pain. 4th one on the passenger side and was under all the other hoses and such and took 3 hours. Second one was just infront of that 3rd one back on passenger side and only took 20 mims without all the stuff in the way. Hopeing the one that is going bad now is a different on so I dont have to get a whole new head if the ones I already fixd blow out again.
There is a technical service bulletin for the V10 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug
1999 Ford F-250 Super Duty- 5.4L V8110,654
plug blow out,
2002 Ford F-250 Super Duty- 5.4L V8113,000
spark plug blew out
2000 Ford F-250 Super Duty- 6.8L V10115,000
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.
2002 Ford F-250 Super Duty- 5.4L V8110,000
#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
2002 Ford F-250 Super Duty- 5.4L V851,000
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.
2001 Ford F-250 Super Duty- 5.4L V8120,000
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.
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