Car Problem Reports

Ford Expedition TSB For Possible Ejection of Spark Plug From Cylinder Head

 
Ford Expedition Problem
21 Reports
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Model Years Affected: 1997, 1998, 1999, 2000, 2002, 2003, 2004

Engines Affected: 4.6L V8, 5.4L V8

Average Mileage: 137,608 mi (11,800 mi - 230,000 mi)

Verified

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.

  • Visitor, , 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.

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  • Visitor, , 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 joanj8598@aol.com

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  • Visitor, , 5.4L V8, 230,000 mi

    Starting sounded like shotgun went off under the hood.

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  • Visitor, , 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.

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  • Visitor, , 5.4L V8

    How many man hours to fix and replace heads if removed?

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  • Visitor, , 5.4L V8, 143,800 mi

    Normal speed engine was at 1500rpms wen I heard a pop started missing and shaking bad

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  • Visitor, , 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.

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  • Visitor, , 5.4L V8, 141,000 mi

    Spark plug blew helix coil repair

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  • Visitor, , 5.4L V8

    bulleted two plugs due to too shallow threading in block
    helicoiled both-1000$ a plug

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  • Visitor, , 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.

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