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: 131,213 mi (50,000 mi - 238,890 mi)
Visitor, 2002 Ford F-150, 4.6L V8
# 3 blow out at 290,890
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.
This has happened to me three times now, I got a kit from O'Riellys that has a longer plug and a deal that retaps the cylinder head. About $65, plus it snaps the coil pack off-everytime-another $60-80 bucks!
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, 2006 Ford F-150, 5.4L V8
2006 problems with F 150 Ford stalling out
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