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: 145,216 (50,000–289,000)
Engines affected: 4.6L V8, 4.9L 6 Cylinder, 5.4L V8, 5.8L V8, V8
13 model years affected: 1991, 1997, 1998, 1999, more2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
59 people reported this problem
40 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 $400.00
1999 Ford F-150- 5.4L V8118,000
The plugs were replaced with Helio coils, new threaded sleeves in the head. Two have ejected. It is limited to the rear on both sides of the heads. Relatively easy fix, if it happens to one, get all 4 rear ones done to save labor. Should be good to go.
2004 Ford F-150- 4.6L V8117,000
1FMRE11W04HA23945 2004 Ford Econoline with 4.6L V8: #2 spark plug ejection from cylinder head.
1999 Ford F-150- 4.6L V8198,000
I had the #4 spark plug blow out while driving down the highway. I'm currently trying to figure out whether or not the threads are stripped.
2002 Ford F-150- 5.8L V8171,000
5.4 v8 # 2 cylinder blew out and also took coil pack with it.
2006 Ford F-150- 4.6L V898,000
Hello my name is Israel and I bought my ford f150 in 2012 used from a dealership this year 2015 around mid march my chamber #3blew destroyed my heating coil stripped the inside good thing the spark plug didn't break I took it in got a new heli coil and everything three days later it blew again now this was the last time a mechanic would do the same thing because he told me if it would to pop again he would have to take everything out rethread chamber number far it hasn't given me any trouble but all in all if ford had recalls these models I wouldn't had spent 600$ to get it fixed and towed...
2000 Ford F-150- 5.4L V8252,354
It was a good truck did everything. I wanted it to do. Then when it started blowing plugs it didn't stop. Even after it was fixed it only lasted a week blew right out again. Now it's blown two plugs and runs on 6 cylinders
1997 Ford F-150- 4.6L V8289,000
was driving for about 4hrs when the #4 plug pop out. The truck sounded like a tank.... called my mechanic and they took care of it with a spark plug coil. a year later same problem driving only for 2hrs and same plug shot out.
2001 Ford F-150- 5.4L V8183,000
#3 plug blew out at 183,000, Has to be tapped with an insert. Should be covered by Ford. If you call the dealer they will likely pretend they dont know about the issue.
2004 Ford F-150- 4.6L V8130,000
Spark plug blew out of head. Threads are bad in the head and plug wi not screw back in.
2000 Ford F-150- 5.4L V8144,000
Spark plug popped out of socket while on the highway piping ignition coil out and almost breaking fuel line.
2001 Ford F-150- 5.4L V8240,000
Had the same issue with my truck. Driving to work one morning heard a loud noise like something hit my truck. Instantly started skipping and smelled fumes. Got to work couldn't fine anything so I called my mechanic and they told me to stop by after work. I told them what happened they laughed said you blew a plug, I said what the h...and they just laughed again and said yep. That's the nature of this engine. I ended up having to replace the head and all the plugs because it stripped the threads beyond a coil working. $1800 and a year later we have started skipping again between 40-50 mph so looks like the same sh.. all over again. May just trade for a Toyota or something.
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