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: 195,064 (51,000–1,820,000)
Engines affected: 5.4L V8, 6.8L V10, V8
42 people reported this problem
26 people shared problem details
2002 Ford F-250 Super Duty- 5.4L V8148,100Visitor
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
2001 Ford F-250 Super DutyVisitor
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.
2003 Ford F-250 Super Duty- 5.4L V8Visitor
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.
1999 Ford F-250 Super Duty- 5.4L V81,820,000Visitor
I put a clinder head repair kit and it blows out again
1999 Ford F-250 Super Duty- 6.8L V10246,392Visitor
It just "blew" out. Easy fix with the head repair tool. It's just a reamer and tap along with the insert from " Matco". I am not a mechanic but I did it myself in under an hour. 256,000 miles now and still going strong.
2002 Ford F-250 Super Duty- 6.8L V10169,400Visitor
F-350 V10 spark plug ejected not fixed yet
2005 Ford F-250 Super Duty- 5.4L V8121,000Visitor
Was driving down the highway and heard a loud bang and then the van lost almost all power and exhaust is extremely Loud coming from the engine area.
2003 Ford F-250 Super Duty- 5.4L V858,000Visitor
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 V8110,000Visitor
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 V8164,000Visitor
Second time a plug blew out. Not sure of the expense yet. Slept in the van on the highway. Diagnosing it now.
2002 Ford F-250 Super Duty140,000Visitor
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 V1070,000Visitor
Happened twice, one at around 70,000 miles, again recently at 90,000.
1999 Ford F-250 Super Duty- 6.8L V10152,550Visitor
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 V8110,654Visitor
plug blow out,
2002 Ford F-250 Super Duty- 5.4L V8113,000Visitor
spark plug blew out
2000 Ford F-250 Super Duty- 6.8L V10115,000Visitor
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 V8110,000Visitor
#6 sparkplug blown out. Not yet repaired.
Our technicians tell us the spark plugs in these engines can be very difficult to remove. Ford...
Will changing the spark plugs on my 2000 F250 5.4 V8 eliminate spark plug ejection problems? Th...
want to do myself but not sure exactly where the # 5 cylinder, spark plug and coil are located...
Just wondering how to change the spark plugs in this truck.