One or More Spark Plugs May be Ejectioned From the Cylinder Head on Ford F-150

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.

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Average mileage: 137,223 (10,000–289,000)
Engines affected: 4.6L V8, 4.9L 6 Cylinder, 5.0L V8, 5.4L V8, 5.8L V8, V8
15 model years affected: 1991, 1997, 1998, 1999, more2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
70 people reported this problem
47 people shared problem details
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..
2006 Ford F-150- 4.6L V8110,000
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! DISSATIFIED FORD OWNER
2003 Ford F-150- 4.6L V8110,029
Solution, buy a Chevrolet.
2003 Ford F-150- 4.6L V889,000
blew spark plug out of cylinder head
2002 Ford F-150- 4.6L V8
# 3 blow out at 290,890
2005 Ford F-150- 4.6L V8109,000
I had it happened at 100,000
2003 Ford F-150- 4.6L V8285,369
has blown number 3 and number 7 spark plugs and coil packs out .
2005 Ford F-150- 4.6L V868,000
4.6 L. Plug blew out, took threads and coil pack with it Repaired with ford kit from NAPA
2002 Ford F-150- 4.6L V8165,000
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
1999 Ford F-150- 5.4L V8118,000
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.
2002 Ford F-150- 5.0L V819,000
Went to the store stopped the car came out started the car and the spark plug blew out. The second one blew out while driving on the highway .
1999 Ford F-150- 5.8L V8
These number lug keeps shooting out Four
2004 Ford F-150- 5.0L V8146,376
Driving and hear a popping noise. Pulled over and look under the hood. Everything look ok. Had a friend start it up for me. And seen a flash on passenger side second spark plug hole from the back of motor (#6 i think) before I could say shut it off my friend turn it off and yelled "was that fire". I responded if it was the engine just sucked it back up. Towed to shop, thay said spark plug ejected recommend re thread. Now fixed and now up for sale, my life is to valued to be going done the road a burst into a ball of flames. Good bye death-trap
2002 Ford F-15091,000
The proper tool and repair kit (TIME-SERT) was about $450 and i knew i couldnt access the rear hole without pulling yhe engine so i opted to have the dealer fix it. Paid dealer to repair the bad threads, replace all 8 plugs and replace the bad coil which broke when the plug came out. Total cost with tax was just over $1000. On the bright side the dealer offers a 2 year warranty on their work so in 23 months they will be replacing the plugs so that I essentially have a perpetual warranty on all treads.
2003 Ford F-150170,000
4.6L V8 Plug #3 I cannot get another plug to thread in, nor can I see inside the hole to assess the condition because of it's location. Unbelievable. Obviously out of warranty. Only problem I ever had up until now was a cooked vacuum hose elbow. I raved about reliability, now the dealer has left me on hold. I don't think they want to touch it.
2009 Ford F-150- 4.6L V875,500
Spark plug blew out coming up a hill. called dealership as I just bought my truck 2 months ago. It is not covered under warranty. Called a ford dealer they didn't have the time of day for me. Called ford corporate, they wouldn't tell me anything. Called another ford dealer they said it eas a defect in the ford f150s. The truck is sitting at a shop waiting to see aobut repair and what all is needing fixed. Thinking it is number six that blew and stripped the threads.
2009 Ford F-150- 4.6L V810,000
Replaced plugs #4 plug ejected while driving after reading this I'm glad to know this is a product problem no more Fords. Still owe $8000 try Chevrolet next
2004 Ford F-150- 4.6L V8117,000
1FMRE11W04HA23945 2004 Ford Econoline with 4.6L V8: #2 spark plug ejection from cylinder head.
1999 Ford F-150- 4.6L V8198,000
I had the #4 spark plug blow out while driving down the highway. I'm currently trying to figure out whether or not the threads are stripped.
2002 Ford F-150- 5.8L V8171,000
5.4 v8 # 2 cylinder blew out and also took coil pack with it.
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