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: 131,536 mi (50,000 mi - 285,369 mi)
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..
Visitor, 2002 Ford F-150, 4.6L V8
# 3 blow out at 290,890
Visitor, 2003 Ford F-150, 4.6L V8, 110,029 mi
Solution, buy a Chevrolet.
Visitor, 2005 Ford F-150, 4.6L V8, 109,000 mi
I had it happened at 100,000
Visitor, 2003 Ford F-150, 4.6L V8, 285,369 mi
has blown number 3 and number 7 spark plugs and coil packs out .
Visitor, 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
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
Visitor, 2003 Ford F-150, 4.6L V8, 89,000 mi
blew spark plug out of cylinder head
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.