Car Problem Reports

Ford F-250 Super Duty TSB For Possible Ejection of Spark Plug From Cylinder Head

Ford F-250 Super Duty Problem
28 Reports
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Model Years Affected: 1999, 2000, 2001, 2002, 2003, 2004

Engines Affected: 5.4L V8, 6.8L V10, V8

Average Mileage: 127,593 mi (51,000 mi - 185,200 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.

  • Visitor, , 5.4L V8, 148,100 mi

    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

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  • 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.

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  • Visitor, , 5.4L V8

    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

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  • BlackCloud, , 6.8L V10, 185,200 mi

    # Four Plug blew out . I have not had it fixed yet as of 10/15 /11.

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  •  Rookie

    Cylinder head number 6 popped out. Local shop used lock tight glue to get new plug back in.

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  • Visitor, , 6.8L V10, 70,000 mi

    Happened twice, one at around 70,000 miles, again recently at 90,000.

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  • Visitor, , 6.8L V10, 152,550 mi

    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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  • mskls, , 6.8L V10, 145,588 mi

    There is a technical service bulletin for the V10 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug

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  • Visitor, , 5.4L V8, 110,654 mi

    plug blow out,

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  • Visitor, , 5.4L V8, 113,000 mi

    spark plug blew out

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