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: 139,156 (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
84 people reported this problem
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Viewing 1 - 20 of 59 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 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
2003 Ford F-150 - 4.6L V8 110,029 mi,
Solution, buy a Chevrolet.
2005 Ford F-150 - 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
2003 Ford F-150 - 4.6L V8 89,000 mi,
blew spark plug out of cylinder head
# 3 blow out at 290,890
2003 Ford F-150 - 4.6L V8 285,369 mi,
has blown number 3 and number 7 spark plugs and coil packs out .
2002 Ford F-150 - 5.0L V8 19,000 mi,
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 .
2002 Ford F-150 91,000 mi,
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.
2002 Ford F-150 87,000 mi,
5.4 Litre Triton. #3 plug blew cruising on highway.
2005 Ford F-150 - 4.6L V8 109,000 mi,
I had it happened at 100,000
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
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.
2005 Ford F-150 - 4.9L 6 Cylinder 150,000 mi,
My engine is a 4.6 8 Cylinder .
2005 Ford F-150 - 4.6L V8 235,000 mi,
05 f150 4.6l parked truck in drive came out next morning started and made a sound of air popping under hood take it to the mechanic and they say it took threads with it so they fix it but u still hear exhaust coming out so I just payed 210 $ for nothing
1999 Ford F-150 - 5.8L V8 178,000 mi,
The engine is a 5.4 Triton.
The so called tool that ford said that can fix my plug. My dealer said will not work. Now I have the cost of having the head pull. Still waiting to see what will be the out come.
2005 Ford F-150 135,000 mi,
No. 6 plug and coil pack blow out while traveling 70 on interstate causing at least 2 bent valves. Mechanic is still working on it to determine the extent of the damage.
2002 Ford F-150 - 5.0L V8 139,000 mi,
Cruising at 60MPH, heard a "Pop", engine light on, loss of power, truck sounded like a LawnMower. I pulled over saw a broken #3 COP and hole where a Spark Plug should be. By the time I had it towed home, went online and discovered this is a huge problem with Ford V8 and V10 motors.
Stranded for a week out of town in middle of nowhere paying for hotel on top of repairs.This is second time having spark plug blow out taking out coil in the process now need new head.ive owned 2 f150s and 4 rangers 1 escort and a mustang.been faithful ford owner but I think it might be time to try on a bow tie