Car Problem Reports

Ford Excursion A Spark Plug Could Blow Out of Cylinder Head

Ford Excursion Problem
19 Reports
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Model Years Affected: 2000, 2001, 2002, 2003

Engines Affected: 5.4L V8, 6.8L V10

Average Mileage: 157,334 mi (76,000 mi - 232,354 mi)


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.

  • , , 6.8L V10, 125,000 mi

    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!!!

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  • , , 5.4L V8, 232,354 mi

    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.

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  • , , 6.8L V10, 194,000 mi

    TThe problem just happened. It's in the shop now to try an d fix.

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  • , , 6.8L V10, 168,000 mi

    third time the plug has been fixed, its a different one each time.

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  • , , 5.4L V8, 156,000 mi

    the front cylinder blew out the spark plug and broke the mount for the coil pack.

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  • , , 6.8L V10, 143,000 mi

    #3 plug drivers side blew out, looks like threads damaged

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  • , , 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.

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  • , , 6.8L V10, 125,000 mi

    I have the same blown spark plug problem and am currently searching for an answer!

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  • , , 6.8L V10, 125,000 mi

    #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.

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  • , , 6.8L V10, 170,000 mi

    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??

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