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.Google+
Car Problem Reports
Ford Expedition TSB For Possible Ejection of Spark Plug From Cylinder Head
Ford Expedition Problem
Engines Affected: 4.6L V8, 5.4L V8
Average Mileage: 137,608 mi (11,800 mi - 230,000 mi)
Visitor, 2002 Ford Expedition, 5.4L V8, 11,800 mi
Number 5 blew while on vacation - setting in the lounge of a Ford dealership waiting for the verdict. This sucks! Ford should reapir this obvious factory defect free of charge.
Visitor, 1998 Ford Expedition, 5.4L V8, 148,629 mi
the spark plug blew out??? WHY WONT FORD DO A RECALL IF THEY KNOW THERES A PRODBLEM WHILE THEY WILL NOT FIX IT. ITS THEIR SCREW UP IWOULD LIKE TO TALK TO SOME ONE IN FORD HEADQUARTERS GIVE THEM A PICE OF MY MIND YOU YOU DO NOT MANUFACTURE A VEHICLE AND DO NOT STAND BEHIND IT .THATS NOT THE AMERICAN WAY . THANK YOU JOAN JACKSON firstname.lastname@example.org
Visitor, 1999 Ford Expedition, 5.4L V8, 230,000 mi
Starting sounded like shotgun went off under the hood.
Visitor, 2004 Ford Expedition, 4.6L V8, 78,090 mi
I was driving an estimated 40 mph up a grade when i heard a loud pop then the engine started to rumble and shake,
I then pulled off the road and turned the engine off.
I looked under the hood, all appeared to be in place, I then started the engine and there was a extremely loud clapping sound, put 2 and 2 together i checked the wires and the #2 plug was gone.
3 thousand miles over my 75,000 factory extended warranty I was out of luck,
It cost me $650.00 to replace 1 coil and 1 plug, a compression test was performed on all cylinders the number two cylinder was five psi low.
The tow truck driver who towed my vehicle to the Ford dealer repair shop told
me that i was the 3rd blown plug vehicle he had picked up this week.
The Ford Motor Company needs to recall the defective heads and stand behind there work and product.
Visitor, 1999 Ford Expedition, 5.4L V8
How many man hours to fix and replace heads if removed?
Visitor, 1998 Ford Expedition, 5.4L V8, 143,800 mi
Normal speed engine was at 1500rpms wen I heard a pop started missing and shaking bad
Visitor, 2003 Ford Expedition, 5.4L V8, 209,590 mi
Driving Fwy speed heard a loud pop and started missing. I was 4 miles away from nearest repair shop and drove there missing. The inserted Helic and replaced the coil pack and replaced all my other Spark Plugs since they hadn't been replaced since I bought in 2003.
Visitor, 2000 Ford Expedition, 5.4L V8, 141,000 mi
Spark plug blew helix coil repair
Visitor, 1998 Ford Expedition, 5.4L V8
bulleted two plugs due to too shallow threading in block
helicoiled both-1000$ a plug
Visitor, 2002 Ford Expedition, 5.4L V8, 120,000 mi
Heard a loud pop, and immediately started missing. Put in insert, new plug, coil, and boot. Hope it makes it another 120,000.