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.Google+
Car Problem Reports
Ford F-150 TSB For Possible Ejection of Spark Plug From Cylinder Head
Ford F-150 Problem
Engines Affected: 4.6L V8, 4.9L 6 Cylinder, 5.4L V8, V8
Average Mileage: 130,870 mi (50,000 mi - 238,890 mi)
Visitor, 2002 Ford F-150, 4.6L V8
# 3 blow out at 290,890
Visitor, 2002 Ford F-150, 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
Visitor, 1999 Ford F-150, 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.
Visitor, 2003 Ford F-150, 4.6L V8, 175,000 mi
Insert in head.
Visitor, 2003 Ford F-150, 5.4L V8, 130,000 mi
I had a similar problem when the spark plug blew out in cylinder 5 at 130,000, and at 135,000 miles it happened again on cylinder 7. I went to NAPA and was told Ford has been having this same problem over the years and they have a Ford cylinder repair kit which sells for $60. Since I have found this to be a common problem and Ford's poor responsiveness in eliminating the problem, I just may go to a Toyota Tundra which has been recommended by a few American mechanics.
Visitor, 2000 Ford F-150, 5.4L V8, 150,000 mi
spark plug blew out and had to replace threads
Visitor, 2006 Ford F-150, 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!
DISSATIFIED FORD OWNER
Went to advanced auto parts. Bought a rubber boot/spark plug kit made specifically for this problem. Drove it like that for 2 years until my number 3 did the same thing right before winter. Will fix the same way until I can afford to by after market heads.
Visitor, 2005 Ford F-150, 4.6L V8, 105,000 mi
#7 Cylinder. 15,000 miles after full tune up where all 8 spark plugs were replaced.
Visitor, 2003 Ford F-150, 5.4L V8, 234,000 mi
Started engine and heard a very loud bang and then immediate loud rattle.