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: 140,489 (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
79 people reported this problem
55 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
2003 Ford F-150- 4.6L V8285,369
has blown number 3 and number 7 spark plugs and coil packs out .
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.
2005 Ford F-150- 4.6L V8109,000
I had it happened at 100,000
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.
2005 Ford F-150- 5.0L V8135,000
Blew out number 7 and 2 different inserts. Been a lifelong diehard ford fan. Not anymore. 135,000 miles.
2004 Ford F-150165,000
4,6 engine....#8...the coil pack blew & pulled spark plug. Stripped the threads in head. Rethreaded it..new plug...new coil pack. Did it again. Owned two Ford's & this will definitely be the LAST
1991 Ford F-150- 5.0L V8175,000
Number 3 spark plug was ejected after a cold start. I was able to clean the threads and put it back in. Don't know how long it will hold.
2004 Ford F-150- 5.0L V8168,000
Spark plug was ejected from head. Adapter and new plug were installed, but was immediately ejected again upon restarting engine. I purchase vehicles for our fleet, and will not buy another Ford product.
2002 Ford F-150180,000
Plug blew out on highway, on our vacation, 500 miles into our journey, last Ford I will own!!
2000 Ford F-150- 5.4L V8
One of the spark plugs was ejected from the cylinder head it was fix but it is still idle rough
2007 Ford F-150240,000
It's not fixed yet
My engine is not listed it's a 4.6L It has the original factory installed plugs 89630 miles on it when going up I-57 with the cruise on it blew a spark plug out the #3 cylinder.
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 .
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