Car Problem Reports

Ford F-150 TSB For Possible Ejection of Spark Plug From Cylinder Head

Ford F-150 Problem
42 Reports
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Model Years Affected: 1991, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Engines Affected: 4.6L V8, 4.9L 6 Cylinder, 5.4L V8, V8

Average Mileage: 131,536 mi (50,000 mi - 285,369 mi)


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.

  •  Rookie

    My truck blowed the #7 spark plug and all threads are gone. I bought a heli coil and installed but does not seal well so it blowed again. Now I'm about to purchase the Dorman cylinder repair kit and cross my fingers. I don't know about the rest of you but this will be the last Ford I ever own. I've always been a mopar fan and came across this truck and something about it just made me have to have it but I will never give in to whatever drawed me to it again and I suggest you don't either. I might not be so judgmental if Ford would do the right thing and fix the issue but we know how BIG CORPORATIONS are don't we. What a joke..

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  • Visitor, , 4.6L V8

    # 3 blow out at 290,890

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  • Visitor, , 4.6L V8, 110,029 mi

    Solution, buy a Chevrolet.

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  • Visitor, , 4.6L V8, 109,000 mi

    I had it happened at 100,000

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  • Visitor, , 4.6L V8, 285,369 mi

    has blown number 3 and number 7 spark plugs and coil packs out .

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  • Visitor, , 4.6L V8, 68,000 mi

    4.6 L. Plug blew out, took threads and coil pack with it
    Repaired with ford kit from NAPA

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  • Visitor, , 4.6L V8, 110,000 mi

    On the way to vacation cylinder 3 ejected from cylinder head-Great way to start vacation. Stranded for 5 hours finely fixed it! Was able to take old plug out and thread new on in and luckily it did not strip, mileage 65,000. Upon return from vacation I changed all spark plugs. At 100,000 miles number 3 popped again! I again was able to replace and it was not striped. And now, number 4 popped. Not so lucky this time- it's stripped, mileage 110,000. CANNOT BELIEVE THERE ARE NO RECALLS, IT'S BS!!!!! I'VE ALWAYS BEEN A FORD GUY BUT THAT ENDS HERE. IF THIS IS HAPPENING TO ANYONE ELSE, PLEASE REPORT IT AND MAYBE FORD WILL DO SOMETHING ABOUT AND STEP UP AND BACK THEIR PRODUCT!


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  • Visitor, , 4.6L V8, 89,000 mi

    blew spark plug out of cylinder head

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  • Visitor, , 4.6L V8, 165,000 mi

    cylinders #2 and #7 blew out on seperate times. i had to have it tapped and use a steel sleeve. mech. said not enough threads on the head. around $400.00

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  • Visitor, , 5.4L V8, 118,000 mi

    The plugs were replaced with Helio coils, new threaded sleeves in the head. Two have ejected. It is limited to the rear on both sides of the heads. Relatively easy fix, if it happens to one, get all 4 rear ones done to save labor. Should be good to go.

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