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

Problem Description and Possible Solution

The Ford F-250 Super Duty has known issues with the V8 engine ejecting spark plugs. This will make a tapping or knocking noise, plus the engine will begin to misfire at all speeds. The check engine light will also illuminate.

The threads on the cylinder head are too short and soft, allowing pressure from combustion to overwhelm and destroy the threads. 

When the spark plug ejects, the cylinder head becomes damaged, necessitating repair of the spark plug port threads, or replacement of the cylinder head and cylinder head gasket. 

Ford has recommended a method of repair for the cylinder head that prevents the spark plug from ejecting under future use. Replacement of all spark plugs is not necessary, but an updated spark plug design can help prevent this from happening in the future. 

There is a technical service bulletin for the V8 engine.

Problem Data
RepairPal Verified
Average mileage: 142,905 (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
77 people reported this problem
Comments
Viewing 1 - 20 of 48 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
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.
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
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.
The back plug on the drivers side came out of the cylinder head and my threads are now damaged.
Sheard manifold bolts off and also ejected spark plug through cylinder head
Started truck to go to work and boom then knocking nose 4th plug on passenger side blow out and tanking out coil with it bought new plug screwed right and tightened down runs fine just got lucky
#3back on passenger side blew out 2 months ago replaced with new plug and heli coil.today11-27-16 same plug blew out again.I don't know why Ford don't recall these vehicles and fix this problem
Blown plug when accelerating from stop sign.
Driver side, rear plug completely blown from cylinder head, ejecting both plug and coil with it.
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.
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.