One or More Spark Plugs May be Ejectioned From the Cylinder Head on Ford Excursion

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.

RepairPal Verified
Average mileage: 160,372 (76,000–232,354)
Engines affected: 5.4L V8, 6.8L V10
4 model years affected: 2000, 2001, 2002, 2003
22 people reported this problem
17 people shared problem details
2003 Ford Excursion- 6.8L V10125,000
Year 2003 also has the problem! I have a 2003 Excursion and I've had 4 spark plugs blown all different ones! BTW who cares what ford authorized!!! They should recall and fix their shitty crap!!!
2000 Ford Excursion- 6.8L V10194,000
TThe problem just happened. It's in the shop now to try an d fix.
2000 Ford Excursion- 5.4L V8232,354
Pulled out from getting gas and heard a loud pop. Took me a while to find that the #3 plug on the driverside blew out of the cylinder now I can't get a new pkug to thread in.
2000 Ford Excursion- 6.8L V10168,000
third time the plug has been fixed, its a different one each time.
the front cylinder blew out the spark plug and broke the mount for the coil pack.
2000 Ford Excursion- 6.8L V10208,347
Driving down the highway about 65 then blam blow out broke the coilpack at the same time sounds costly havny figured out how to fix yet thanks Ford for the support
2001 Ford Excursion- 6.8L V10161,000
The rear plug on the driver's side blew out when I started pulling my trailer. $900 later, I am crossing my fingers and toes hoping it won't happen again before I can sell this crappy thing.
2001 Ford Excursion- 6.8L V10143,000
#3 plug drivers side blew out, looks like threads damaged
2000 Ford Excursion- 6.8L V10
I had #9 cylinder blow the sparkplug out stripping the treads and braking the ingnition coil. I was traveling through NH, and there was a Ford Dealer there that was able to put a new tread insert, replaced the sparkplug And coil pak. but didn't set the timeing for the new pak seeing that I had replaced all of them last summer with a differant brand, the truck did run but not rite, I order one to match the others. I hopr the rest of the plugs don't blow out aswell. at $330.00 per cyl. might be cheaper to replace the heads.NEW.
2000 Ford Excursion- 6.8L V10125,000
I have the same blown spark plug problem and am currently searching for an answer!
2000 Ford Excursion- 6.8L V10125,000
#3 spark plug blew out yesterday, classic case, had no clue this was a problem with Ford until I started googling yesterday, going to have to pay out the hiney to fix.
2000 Ford Excursion- 6.8L V10170,000
I had 1 replaced about 10k ago and now another one blew out of the cylinder. repair tech said it has already had the thread repair on that cylinder. How??? I bought this vehicle brand new off the lot.......REALLY come on Ford what the cuss??
2000 Ford Excursion- 6.8L V10155,000
2 seperate occurrances of a single spark plug being ejected, starting around A-75,000 miles and a different plug, B-125,000 miles. This Excursion is not used for towing; It has a normal (easy?) duty cycle. After second ejection, all on the drivers side, all unaffected spark plugs holes were repaired anticapating additional, new failures. No apparant failures on the passenger side of V10. One blowout, A-75,000 miles, that was repaired, cylinder #9, appears to be failing again, possibly because the new spark plug was cross-threaded into the repaired cylinder head.
2001 Ford Excursion- 6.8L V10215,000
Suddenly blew out plug on way to work - no issues prior - been about 60K since last tuneup
2000 Ford Excursion- 6.8L V10180,000
My husband was setting with idle and all of a sudden he heard loud popping noise. Ywp it was the sparkler blown out and stripped the threads. Havent had it fixed, is it covered under warrenty??/ HMMM wonder
2000 Ford Excursion- 5.4L V8150,000
Two spark plugs have blown out of the heads in the past 8 weeks and fords recalling for fuel tank straps WHY not for this major problem ??????????
2000 Ford Excursion- 6.8L V10134,000
just happened to me today and i need to replace corpak and im sure spark plugs
Related Items:
I am considering buying a 2000 excursion. I've heard horror stories about the spark plugs blowi...
I'm old school and when I looked for the sparks plugs I chould only find what appeared to be so...
tapping mostly happens after warm up truck has 140000 miles on it and i changed oil religiously...
my excursion has been acting up since i used gas from a different gas station. my suv seem to b...

Related Content