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.
One or More Spark Plugs May be Ejectioned From the Cylinder Head on Ford F-250 Super Duty
Average mileage: 140,786 (51,000–246,392)
Engines affected: 5.4L V8, 6.8L V10, V8
57 people reported this problem
2002 Ford F-250 Super Duty - 5.4L V8 148,100 mi, Visitor
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
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
# Four Plug blew out . I have not had it fixed yet as of 10/15 /11.
2002 Ford F-250 Super Duty - 6.8L V10 169,400 mi, Visitor
F-350 V10 spark plug ejected not fixed yet
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.
Spark plug piped out while driving smoke came from under dash wasn't to happy. How much will it cause to put new thread in engine.
Sheard manifold bolts off and also ejected spark plug through cylinder head
2001 Ford F-250 Super Duty - 5.4L V8
Spark plug blew out of cylinder head destroying threads,plug, and coil. Inserted new thread kit . Lasted about two years just did it again a couple weeks ago
2002 Ford F-250 Super Duty - 5.4L V8
Spark plug blow out
2002 Ford F-250 Super Duty - 6.8L V10
Spark plugs have been ejected twice from the V10 engine. At about 100K mile the first plug was ejected. Dealer inserted helicoil in damaged cylinder head. At that point the dealer replaced all remaining plugs. At 115K miles a second plug, different from the first, was ejected. That cylinder head was repaired by the dealer with a helicoil also. This is a design defect that Ford ought to repair for free.
2001 Ford F-250 Super Duty - 6.8L V10 56,000 mi, Visitor
ejected plug , fixed with insert
2002 Ford F-250 Super Duty - 6.8L V10 133,000 mi, Visitor
Spark plug blew Out can not repair.
2005 Ford F-250 Super Duty - 6.8L V10 231,000 mi, Visitor
blew out forth back on passenger side
2000 Ford F-250 Super Duty - 5.4L V8 140,000 mi, Visitor
One blew out while driving down the road, apparently just loosened over time. Repaired it with a Dorman 42025 HELP! Kit. Replaced remaining 7 plugs. About 6 months later another plug on the same head, driver side, did the same thing. Repaired it in the same manner, Been about 45,000 miles since then.
2000 Ford F-250 Super Duty - 6.8L V10 90,000 mi, Visitor
Have blown plugs 12 times 1 st one in 2008 two in 2010 4 in 2014 and 5 more in the last year she got 200,000 miles now she is a witch seems to do it when we really need her or when we don;t have much money:: we used our young ones school money for to make it work Damn them fellers that made that engine gramma has put a Bad curse 0n them"" seen them work too why don't they recall em;
2007 Ford F-250 Super Duty - 5.4L V8 170,000 mi, Visitor
Loss of power when climbing hills. Problem is sparks plugs and coil packs will not tighten down for some reason they strip out on their own. Ford needs to perform the maintenance on these super duty trucks.
still not fixed lost #3 cylindr and #4 cylinder 2 times on each
2003 Ford F-250 Super Duty - 5.4L V8 90,000 mi, Visitor
Not sure which but right bank 2nd or 3rd one back.. At garage my guy has done a ton of these.. Was starting down a incline and sort of sounded like a jake break... Have a old Chevy I was getting ready to sale but I think I will keep it till I can afford something a lot newer
2004 Ford F-250 Super Duty - 5.4L V8 180,000 mi, Visitor
Twice now Ive blown the same coil on my 2004 f-250 super 5.4L engine
I put a clinder head repair kit and it blows out again