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

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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Average mileage: 138,481 (51,000–246,392)
Engines affected: 5.4L V8, 6.8L V10, V8
8 model years affected: 1999, 2000, 2001, 2002, more2003, 2004, 2005, 2007
48 people reported this problem
31 people shared problem details
2002 Ford F-250 Super Duty- 5.4L V8148,100
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
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.
# Four Plug blew out . I have not had it fixed yet as of 10/15 /11.
2002 Ford F-250 Super Duty- 6.8L V10169,400
F-350 V10 spark plug ejected not fixed yet
2000 Ford F-250 Super Duty- 6.8L V1090,000
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;
2007 Ford F-250 Super Duty- 5.4L V8170,000
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
2003 Ford F-250 Super Duty- 5.4L V890,000
Not sure which but right bank 2nd or 3rd one back.. At garage my guy has done a ton of these.. Was starting down a incline and sort of sounded like a jake break... Have a old Chevy I was getting ready to sale but I think I will keep it till I can afford something a lot newer
2004 Ford F-250 Super Duty- 5.4L V8180,000
Twice now Ive blown the same coil on my 2004 f-250 super 5.4L engine
I put a clinder head repair kit and it blows out again
1999 Ford F-250 Super Duty- 6.8L V10246,392
It just "blew" out. Easy fix with the head repair tool. It's just a reamer and tap along with the insert from " Matco". I am not a mechanic but I did it myself in under an hour. 256,000 miles now and still going strong.
2005 Ford F-250 Super Duty- 5.4L V8121,000
Was driving down the highway and heard a loud bang and then the van lost almost all power and exhaust is extremely Loud coming from the engine area.
2003 Ford F-250 Super Duty- 5.4L V858,000
I put the insert in w/plug and new coil pack. After replacing 3 other ones, the first replacement blew out!! I now have to replace the head on a 2003 with 61,000 miles!!!!
2001 Ford F-250 Super Duty- 5.4L V8110,000
spark plug ejected out of cylinder head at approximately a hundred ten thousand miles mechanic told me second time this is happened to same cylinder I had to order special tool from California will not be able to fix next time also said on any Ford made out of a certain plant this is a common problem could be in a Mustang and a truck etc
1999 Ford F-250 Super Duty- 5.4L V8164,000
Second time a plug blew out. Not sure of the expense yet. Slept in the van on the highway. Diagnosing it now.
Cylinder head number 6 popped out. Local shop used lock tight glue to get new plug back in.
2000 Ford F-250 Super Duty- 6.8L V1070,000
Happened twice, one at around 70,000 miles, again recently at 90,000.
1999 Ford F-250 Super Duty- 6.8L V10152,550
Two plugs blow out on the passenger side within a year and now I feel like its happeneing again. Same kinda before symptoms. But me and my dad replaced both with a helia coil ( however you spell it) I think there was one other part but ordered from Napa amd was only 75 bucks or so. The first one was a pain. 4th one on the passenger side and was under all the other hoses and such and took 3 hours. Second one was just infront of that 3rd one back on passenger side and only took 20 mims without all the stuff in the way. Hopeing the one that is going bad now is a different on so I dont have to get a whole new head if the ones I already fixd blow out again.
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