Ignition Coil Failure Due to Excessive Spark Plug Gap on Ford F-150

Problem Description and Possible Solution

An illuminated Check Engine Light and a rough running engine could indicate that one or more of the ignition coils has failed. Often times this is due to excessive spark plug gap. To fix this problem, the defective ignition coilsspark plugs, and all coil boots should be replaced.

Problem Data
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Average mileage: 129,237 (48,876–408,000)
Engines affected: 4.2L V6, 4.6L V8, 5.4L V8, 6 Cylinder, V8
15 model years affected: 1997, 1998, 1999, 2000, more2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011
156 people reported this problem
Viewing 1 - 20 of 55 comments
What is happening with these coils going is a few things. First the spark plug could be bad causing the coil to go and secondly the plug wire ends if they do not have di-electric grease packed in both ends, the least bit of moisture is enough to screw it up. These models have been known to have a bad design as far as the coils (in which #5 and #7 are ususally the culprits ) of letting water in the wells where the plug is. I am experiencing it also but have found a guy that knows exactly how to fix the problem. My conversation had just started and he stopped me and said, " Let me guess, this is whats happening " and he was spot on and continued to tell me how he has fixed them.... two weeks before he can get to it though....grrrrrr.
A couple years ago I was driving home and all the sudden engine light came on and car started sputtering/ misfiring around 50 miles per hour. Had full tune up done which cost a lot of money, replaced all spark plugs and coils. Since then every few months same issue with 1 coil = #5. Replace spark plug and coil/boot assembly and good for another couple months, pain in the butt. UNHAPPY Truck has been taken care of ... only has 115,000 miles and should not have to deal with this every few months :(
If the spark gap is set to Ford's spec.s, what the h... is the gap that will keep the d... coils from blowing. I have experienced failures about every 3 to 6 months for the last couple of years. Going send me right back to Jap trucks.
Vehicle started skipping intermittently, expecially noticable when I accellerated. I replaced the ignition coil.
Multiple Coil failures...caused Catalytic converter failure. All spark plugs coils have been replaced by the dealer more than once. My truck continues to have coil issues. problem not resolved.
i was driving and i herd a pop like something hit my hood and then the truck sounded like a motorcycle, i took it to a friend and he said the # 4 plug popped out. so he fixed it for me but a year later i still have problems with misfire on #4 had new boots put in but every six months still misfires
Trucks misfiring and I am constantly having to replace #6 coil like every 2 months it's so frustrating and the truck runs like crap even after the coil has been replaced
Bought used truck with 100K on meter; at about 120K, the engine began eating coils about 1 each year for the last couple of years. First was #4 in the summer, then #6 the following spring, now, #5 in the mid of winter. "Check Engine Light" didn't come on until the miss was very bad.
engine was missing between 40-50 mph until the check engine light was continuosly lit no codes were revealed. mine was the number 1 cylinder i replaced just the one as 1,000 for all 8 is out of my budget.
Jumping between 45-55 mph. Disappears after 60mph. Will try replacing coils and plugs as suggested.
check engine light came on.....ran rough, took to repair shop and had them plug into it to check the codes and sure enough the number four cylinder misfires.
Engine light came on ran test with scanner found a miss fire code. Found bad coil removed spark plugs all where bad along with one coil. 2 of the spark plugs where stuck in the head and had to be removed coasting extra money. now it runs great.
Replaced #7 coil because it was missing. Returned it to the garage because the problem wasn't fixed.
Replaced #7 again.
A week and half go by and it started doing the same thing.
Service engine light has not come on yet, but it will be going back to the garage asap.
this engine stinks and so does these plugs Ford ought to be ashamed of themselves for not giving they're costumers more support on a problem that is clearly a manufacter deficit
I had a misfire and took it in, mechanic replaced the ignition coil. Ran fine for another year (but I don't drive much, so only about 4,000 miles) then another coil went out. I had that replaced, then another month and about 2,000 miles later ANOTHER coil went out.
By this time, I was tired of paying the mechanics so I did it myself which was pretty cheap, about $75 and 30 minutes. Another 500 miles and another coil is acting up. I'm selling the truck.

Perhaps there is something you can do with the spark plug gaps, but I don't know what it is. All I know is my next truck will be from Toyota or Nissan.
For no apparent reason engine started running rough, I thought I had a flat tire at first. Made it to repair facility auto tech confirmed issue was related to ignition coil failure on number seven cylinder. Cost me 200 bucks to get it fixed. Ford may have put this engine together in Michigan but the parts associated with the problem were made in Mexico. Thanks NAFTA and Ford, i'm spent $40,000 on this truck for quality and that is what I expect.