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: 136,369 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, 1999 Ford Expedition, 5.4L V8, 125,000 mi
Bought our 99 Eddie Bauer used, knew there was a stripped plug at the time, but it was supposedly repaired. We've had this truck for 2 years now, gone through 6 coils and plugs as well as 2 of these stupid "Ford Approved" repair kits. Their approved repair isn't a solution, only a band aid and shame on Ford for not acknowledging their mistake and fessing up to repairing these vehicles! My only permanent solution now is to replace the heads (of course, having a qualified machine shop re-thread the spark plug holes PROPERLY this time). In the mean time, having to deal with occasional stalls and coil burn outs has become the normal operating condition of my truck!
Shame on Ford! Shame on me too for not doing a proper google on this truck BEFORE I bought it!
Visitor, 2000 Ford Expedition, 4.6L V8, 143,000 mi
Was driving at freeway speed(65 mph) heard a kabang but vehicle continued to run, no check lights, no other weird noises. 80 miles later it throws a service engine soon light, begins to skip and miss as it drives. I get it home, I grab the code reader, plug it in, cycle it, get several that are nonsense codes(come as 'no code' but prompts one) and a spark plug 3 failure. I open hood peer inside figure aliens built this thing I couldn't find spark plugs until I broke out the Haynes repair manual and even then that was a joke for what it was buried under. Decided I can change them on a GM but this is beyond me paid the former ford dealer mechanic 300 bucks to replace my spark plugs. Number 3 had exploded, burned out and damaged the Heli coil. Heli coil was replaced. Vehicle 21k miles later still won't run smooth, service engine soon light now flashes constantly. Took it to actual Ford dealer, they insist all my spark plugs and coils are fine and cannot pull a code for what is failing. Put it on a Dyna-meter to fail it under speed, and it STILL wouldn't throw a code. All plugs and coils visually inspected, no issues. Dealer recommending replacing entire engine, at 154001 miles.
Visitor, 1999 Ford Expedition, 4.6L V8, 125,000 mi
Two of my spark plugs blew from the cylinder and I had to buy rethreading kits to repair car still runs a little shaky
Visitor, 1998 Ford Expedition, 5.4L V8
I have had spark plugs and coil pack replaced twice in a year. The second time it had to be rethreaded. Its starting to act up again.
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, 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.