Expedition Spark Plug Ejection

Hi all, new to the site. I'm doing some research on what I thought was a unique problem, but I'd like to see as it may not be as unusual as I thought. It seems one of the spark plugs blew clean out of the head last week. Preliminary research indicates that this is a design defect that is not all that uncommon (and not being acknowledged bby Ford - nice how they stand behind their vehicles, huh?). The heads are aluminum and the threads aren't deep enough and over time they strip and eject a plug. The dealership insists this isn't that common but a quick check on consumeraffairs.com revealed 15 cases listed on just that site. I'd like to find out how common this is and if anyone has had any luck getting their warrenty company to cover it. I'm currently fighting with EZ Care but I'm afraid I'm up against a precedent setting situation so they are going to fight it tooth and nail.
Also. has anyone had anyluck with heli-coils or similar re-tapping procedures?

Thanks for all responses

Is it "common"? NO. Does it happen? YES.

Cause: Spark knock. When you have excessive (not necessarily audible) spark knock, the cyliner pressure can increase to 3x-10x higher than designed for, and as you discovered you get plug "blow-out".

This is generally seen on vehicles where the plugs are NOT factory and have been changed and either over or under torqued, but it can and does happen with factory plugs at low mileages.

Is it a warrentable condition (factory plugs), DEFINATELY!

The Ford dealer in Wyoming where we spent 5 days of our vacation unexpectedly told me that it was a very common problem. After replacing the cylinder head (and the exhaust manifold which broke in the process of removing it) and shelling out $2,200.00 for the repairs and $350.00 for lodging I was on my merry way.

I initially though I had blown a cylinder head gasket, but the mechanic who worked on it told me it was a blown spark plug on one of the rear cylinders before he even opened the hood. This same dealership had experienced several other instances of this same problem within the last year. They refused to try putting in a Helicoil as they would have to remove the head anyway to get at it.

I had zero success in getting Ford to pick up any part of the cost. That was my 6th new Ford purchase and my last.

I also had the same problem with a blown spark plug. I have spoken top Ford and the Ford dealer and they were not of any help. Ford dealer stated only way that Ford Motor Company would help is if there was a recall but he doesn’t see that there will be…maybe if more of us complain. I remember seeing on the internet where some were trying to get a class action lawsuit against Ford...I’m game for this. I’m going to keep hounding Ford Motor Company until they get tired of me… I did manage to get mail from one of their execs but got the run around. After that I sent a letter to their Board Of Directors and will continue to do so until they acknowledge my complaint and at least help pay for the repairs. I ended up paying $2745.00…

Ford has unofficially admitted they "have a problem" with 4.2, 4.6, 5.4 and 6.8 litre engines in respect to blowing sparkplugs out of their heads.
They usually blow on the right bank(passenger side)
usually one of the last two plugs. This is a "pattern failure". Ford has been warrantying and "back dooring" a lot of cylinder heads($1200 each, retail)
I operate a relatively small fleet of Fords, and have experienced two plugs blown out in the past two years. One was a 6.8 V-10 (# 4 plug) and the other was a '98 Expedition 5.4 (#3 plug).
Ford replaced the head on the V-10 " as a Goodwill gesture", they "back doored" us a new cylinder head and gaskets (act of good faith)
I'm not a "Ford Expert", but find some of them extremely hard to work on.
Latest problem? Exhaust manifold studs(factory installed) They break on the rear most cylinders causing exhaust leaks.

Ford has unofficially admitted they "have a problem" with 4.2, 4.6, 5.4 and 6.8 litre engines in respect to blowing sparkplugs out of their heads.
They usually blow on the right bank(passenger side)
usually one of the last two plugs. This is a "pattern failure". Ford has been warrantying and "back dooring" a lot of cylinder heads($1200 each, retail)
I operate a relatively small fleet of Fords, and have experienced two plugs blown out in the past two years. One was a 6.8 V-10 (# 4 plug) and the other was a '98 Expedition 5.4 (#3 plug).
Ford replaced the head on the V-10 " as a Goodwill gesture", they "back doored" us a new cylinder head and gaskets (act of good faith)
I'm not a "Ford Expert", but find some of them extremely hard to work on.
Latest problem? Exhaust manifold studs(factory installed) They break on the rear most cylinders causing exhaust leaks.


Samw - How did you get Ford to replace the head as a good will gesture... I have written to Ford and looks like they will not move ontheir stance to help me.

The "goodwill gesture" on their part was mostly because the fleet I maintain contains roughly 450 Fords. And the new fiscal year just started. Besides, I'm one of their biggest customers.

If you're just one insignificant person, Ford's stance is usually "Sorry Charlie."

You might check around, I understand there are several Class Action Suits being filed on behalf of Ford owners nationwide.

Thanks.. I heard that tere were some clas action suits but have been unable to find them on the internet...will keep searching..thanks again..

Check NTSHA and Consumer Affairs web pages.
There is a company that manufactures a spark plug insert guranteed not to blow out.
It's expensive, but not as bad as replacing a whole cylinder head.
Their web-page address is: timesert.com
I think a kit to cut, tap, and insert their thread insert costs about $300, but it can be used multiple times.

ModMech mentioned that plugs are blown out by detonation. Both of the vehicles in my fleet that did blow out plugs haven't shown any signs or complaints regarding detonation, before or after the heads were replaced.
We did have a couple of Crown Victorias down in the Colorado River area (at sea level) that were experiencing detonation, but a quick reflash for low altitude service and resetting the octane selector cured that.

All of the blown plugs were factory installed, by the way.
I think Ford has a serious design flaw in the "modular" engine.

Sorry so late to this thread but I handle cylinder heads on a daily basis and I do know that on the 4.6 for example on the newer ones the spark plug threads are twice as long as the older ones, must be a coinsidence.
And about 1 out of 4 have a broken exhaust manifold stud.

Hopefully, Ford has redesigned their cylinder heads.
They also need to redesign their manifolds. As Wilfie27 said, one out of four have broken studs when he gets them. In the field it's more like one in three. The manifolds curl up like old 454 manifolds used to. Fortunately, they snap off the studs instead of pulling them out. Remanufactured engines we get come with sixteen new studs and sixteen new manifold nuts. They must know something Ford don't.

This happened to me last night while driving my 1999 motor home. I bought it new and it only has 44,300 miles on it. Never had the sparkplugs changed. Mechanic at the local Ford dealer told me he has seen this before several times and even had one comein with only 10,000 miles on it. I just got a quote of $4500 + tax to fix!!! So I am going to be into this repair for $5000.

This sucks Mr. Ford!

I too had a plug blow out twice in My 2000 ford Excursion V10. Mine Blew out on the passenger side second from the rear of the engine. It completely destroyed my Coil Pack by banging against the fuel rail. They were the original Motorcraft plugs.

Please follow the link (or cut and paste into your address bar) and sign the petition. It may help us all in the end. We need every person this has happened to to make their voice heard.

http://www.ipetitions.com/petition/R...ITY/index.html (http://www.ipetitions.com/petition/RELIABILITY/index.html)

Just skip the donation page at the end.

Jack

I personally have not had one blow out but I know people that have. They all had them fixed by a Blownoutsparkplug.com. They have their own style of inserts that I have not seen anywhere else. They came out and did everything right here including changing all of the other plugs and checking the treads. They even guaranty their repair. I would contact them. Their site is http://www.blownoutsparkplug.com

Usa tools on ebay sells an OTC repair kit. Pull the plug drill it out tap and install insert. 14 inserts in the kit. Otc makes ford specialty tools. The kit has a vacuum attachment for removing metal shavings. Cost $89.00 plus shipping probably double that on a tool truck. I purchased a Torx Plus set from him for $50.00 mfg. by OTC. I ordered on the weekend and they were shipped UPS on monday. He had to order the TR55 and TR60 and they were shipped from OTC. in Minn. He is located in Ohio.
The kit is designed for a 5.4l. By the time you pull the head and fix it I would buy the kit cheaper than gaskets.
I've always had good success with OTC Tools.

I own a 2000 F250 V10 super duty and I used a kit by Time-Sert to repair my spark plug it was a little time consuming because I had never done something like this before but it worked EXCELLENT! My truck is running smooth I am so thank full I could repair this without removing the head which would have taken a ton of time on a lifted V10.
www.timesert.com (http://www.timesert.com)
This is the kit I used called ford kit check out the repair video its helps understand the process. :)
http://www.timesert.com/html/triton_repair2.html

James

manifolds curl up like old 454 manifolds used to. Fortunately, they snap off the studs instead of pulling them out.thread insert (http://www.xhcljx.com/eng) helicoil (http://www.xhcljx.com/eng)