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One or More Spark Plugs May be Ejectioned From the Cylinder Head on Ford F-150

Problem Description and Possible Solution

The Ford F-150 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: 140,866 (10,000–289,000)
Engines affected: 4.6L V8, 4.9L 6 Cylinder, 5.0L V8, 5.4L V8, 5.8L V8, V8
15 model years affected: 1991, 1997, 1998, 1999, more2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
110 people reported this problem
Comments
Viewing 1 - 20 of 67 comments
On the way to vacation cylinder 3 ejected from cylinder head-Great way to start vacation. Stranded for 5 hours finely fixed it! Was able to take old plug out and thread new on in and luckily it did not strip, mileage 65,000. Upon return from vacation I changed all spark plugs. At 100,000 miles number 3 popped again! I again was able to replace and it was not striped. And now, number 4 popped. Not so lucky this time- it's stripped, mileage 110,000. CANNOT BELIEVE THERE ARE NO RECALLS, IT'S BS!!!!! I'VE ALWAYS BEEN A FORD GUY BUT THAT ENDS HERE. IF THIS IS HAPPENING TO ANYONE ELSE, PLEASE REPORT IT AND MAYBE FORD WILL DO SOMETHING ABOUT AND STEP UP AND BACK THEIR PRODUCT!

DISSATIFIED FORD OWNER
4.6 L. Plug blew out, took threads and coil pack with it
Repaired with ford kit from NAPA
My truck blowed the #7 spark plug and all threads are gone. I bought a heli coil and installed but does not seal well so it blowed again. Now I'm about to purchase the Dorman cylinder repair kit and cross my fingers. I don't know about the rest of you but this will be the last Ford I ever own. I've always been a mopar fan and came across this truck and something about it just made me have to have it but I will never give in to whatever drawed me to it again and I suggest you don't either. I might not be so judgmental if Ford would do the right thing and fix the issue but we know how BIG CORPORATIONS are don't we. What a joke..
The so called tool that ford said that can fix my plug. My dealer said will not work. Now I have the cost of having the head pull. Still waiting to see what will be the out come.
Went to the store stopped the car came out started the car and the spark plug blew out. The second one blew out while driving on the
highway .
The proper tool and repair kit (TIME-SERT) was about $450 and i knew i couldnt access the rear hole without pulling yhe engine so i opted to have the dealer fix it. Paid dealer to repair the bad threads, replace all 8 plugs and replace the bad coil which broke when the plug came out. Total cost with tax was just over $1000. On the bright side the dealer offers a 2 year warranty on their work so in 23 months they will be replacing the plugs so that I essentially have a perpetual warranty on all treads.
The plugs were replaced with Helio coils, new threaded sleeves in the head. Two have ejected. It is limited to the rear on both sides of the heads. Relatively easy fix, if it happens to one, get all 4 rear ones done to save labor. Should be good to go.
I am purchasing the Truck (4x4 Triton F-150) from a buy here pay here (hole in the wall) car lot! I only put 20 miles maybe on it! It was running ruff, got codes read and 1,2,7&8 are misfiring plus 3 other codes. Anyway went out to start the truck yesterday heard a loud back fire then what I thought was a exhaust leak, thinking the valve cover blew drove to gas station .5 mil. up the St. popped the hood and there was my #2 spark plug laying on the valve cover and the part of the coil that bolts to the head busted off bolt still in tacked! Got it home and been looking for a CHEAP BUT GOOD Mechanic to re sleeve the cylinder(s).
About 2 months ago, cylinder #3 blew the spark plug. Heli-coil was the recommended repair. Just this past weekend, cylinder #3 blew the spark plug again, this time damaging the head. Now I'm waiting to see if the head can be repaired or if it's going to have to be replaced. Not looking forward to this estimate. Really wish Ford would take a look at the number of models and model years that are having this issue. Clearly, it should be a recall.
Spark plug blew up. I used a heli coil repair kit. However. now I am not able to remove and change the spark plug
05 f150 4.6l parked truck in drive came out next morning started and made a sound of air popping under hood take it to the mechanic and they say it took threads with it so they fix it but u still hear exhaust coming out so I just payed 210 $ for nothing
cylinders #2 and #7 blew out on seperate times. i had to have it tapped and use a steel sleeve. mech. said not enough threads on the head. around $400.00