One or More Spark Plugs May be Ejectioned From the Cylinder Head on Ford F-250 Super Duty

Problem Description and Possible Solution

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.

Problem Data
RepairPal Verified
Average mileage: 139,383 (51,000–246,392)
Engines affected: 5.4L V8, 6.8L V10, V8
9 model years affected: 1999, 2000, 2001, 2002, more2003, 2004, 2005, 2006, 2007
66 people reported this problem
Viewing 1 - 20 of 43 comments
Just today 12/15/13 driving 30 MPH. It is the first cylinder on the passenger side. #? I've read this is a extremly common problem, and I don't have the funds for repair. No longer a Ford enthuiast. Brian
Started my vehicle today, 12/15/2012, at the mall and..boom!! then some smell of smoke inside the vehicle ...then more popping which sounded almost like a belt slapping against something under the hood. I had no prior indication of a problem except yesterday morning there was a vibration in the steering wheel while accelerating that stopped once letting off the gas. It did smooth out within 45-60 seconds and did not reoccur. Then today's issue occurred. I had the truck, F-250, 2003 Quad Cab, with 150-K miles towed to the Ford dealership about a mile away which was the place of original purchase. Initial estimate to repair it..$700.00; not a happy christmas gift
Spark plugs have been ejected twice from the V10 engine. At about 100K mile the first plug was ejected. Dealer inserted helicoil in damaged cylinder head. At that point the dealer replaced all remaining plugs. At 115K miles a second plug, different from the first, was ejected. That cylinder head was repaired by the dealer with a helicoil also. This is a design defect that Ford ought to repair for free.
F-350 V10 spark plug ejected not fixed yet
# Four Plug blew out . I have not had it fixed yet as of 10/15 /11.
Spark plug piped out while driving smoke came from under dash wasn't to happy. How much will it cause to put new thread in engine.
The Spurk on engine v10 shoot out and lost power...the attached plastic cable broken with the bang... It just happened after I stop in a sign stop and moved... It sound like bang... And the engines kept running but making loud bang... No power to drive. My cost to repair was is $200 plus I had to pay towing.
The car has been own by me for two years.
The back plug on the drivers side came out of the cylinder head and my threads are now damaged.
Spark plug #8 blew out of the cylinder head. I was stopped at a red light, when I tried to take off the engine made a popping noise and I could hear what sounded like a vacuum leak. Looks to be original plugs.
First incident was 29 March 2016. An insert was put into the affected cylinder spark plug hole. Worked fine until yesterday, 6 May. Same cylinder ejected spark plug. Towed it to a shop. Engine had ingested part of blown spark plug. Pulled heads on both sides. Sent to machine shop to have all holes repaired. Est is $3500. Still waiting for completion as it is the weekend.
Sheard manifold bolts off and also ejected spark plug through cylinder head
Spark plug blew out of cylinder head destroying threads,plug, and coil. Inserted new thread kit . Lasted about two years just did it again a couple weeks ago
Spark plug blow out
ejected plug , fixed with insert
Spark plug blew
Out can not repair.
blew out forth back on passenger side
One blew out while driving down the road, apparently just loosened over time. Repaired it with a Dorman 42025 HELP! Kit. Replaced remaining 7 plugs. About 6 months later another plug on the same head, driver side, did the same thing. Repaired it in the same manner, Been about 45,000 miles since then.
Have blown plugs 12 times 1 st one in 2008 two in 2010 4 in 2014 and 5 more in the last year she got 200,000 miles now she is a witch seems to do it when we really need her or when we don;t have much money:: we used our young ones school money for to make it work Damn them fellers that made that engine gramma has put a Bad curse 0n them"" seen them work too why don't they recall em;
Loss of power when climbing hills. Problem is sparks plugs and coil packs will not tighten down for some reason they strip out on their own. Ford needs to perform the maintenance on these super duty trucks.
still not fixed lost #3 cylindr and #4 cylinder 2 times on each