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Ford F-150

Report: TSB For Possible Ejection of Spark Plug From Cylinder Head

Ford F-150 Problem
14 Reports
Me Too Edit

Model Years Affected: 1991, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Engines Affected: 4.6L V8, 4.9L 6 Cylinder, 5.4L V8, V8

Average Mileage: 153,881 mi (94,000 mi - 238,890 mi)

Verified

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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  • Report #1
    Visitor, 1991 Ford F-150, 4.9L 6 Cylinder

    new spark plug

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  • Report #2
    Visitor, 1999 Ford F-150, 137,400 mi

    #2 plug blow out problem on 5.4 in my 99 f1504x4

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  • Report #3
    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.

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  • Report #4
    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

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  • Report #5
    Visitor, 1991 Ford F-150, 238,890 mi

    I have now replaced 3 blown out plugs 5.4 ltr with helio coils.FORD should Step up to the Plate and Help pay for new heads or have them machine new heads with new threads to eliminate this problem.This Truck has been fabulous to this point. I hate to have to change my Brand of truck for the next purchase. Roger Corbiere

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  • Report #6
    Visitor, 2001 Ford F-150, 4.6L V8, 94,000 mi

    3000 miles after a tune up the number 3 cylinder ejected a spark plug a couple of thousand miles later the number 5 clyinder ejected a spark plug.
    I am now in the market for a Tundra or a Ram 1500 or a Silverado.

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  • Report #7
    Visitor, 2002 Ford F-150, 5.4L V8, 170,000 mi

    I have had three spark plugs eject over the last two years or so and the number 2 plug just ejected again and my mechanic says I need to replace the head because the aluminum melted around the threaded hole and he can't fix it again with a helicoil.

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