99 CVP71 130K. While driving sparkplug popped out.

[alotech]

While driving on the frwy on my way to work this morning I started hearing a loud popping noise from my engine and it started running rough. I thought I had tore up the manifold going through a large water puddle since it was raining hard. After work I started the engine and noticed one of the ignition things that attaches to the spark plug boot was bouncing. When I went to grab it, the spark plug came out with it. When I tried to reset the plug, it just fell back in the hole. There was no thread on the engine, but it looked ok on the plug. What caused this? What is the fix? And is this a symptom of another problem? Thanks in advance.

[rhandwor]

You can go to Advance Auto and buy a spark plug repair kit. They cost $38.00 they come with 3 length plug inserts. They have a ream on the tap. It takes a 3/8 inch extension and a ratchet. Measure the thickness if this is a COP setup
it will take the long insert. As the plug sets in a well use an old 14mm plug with the washer removed to install the insert. Use red silicon to seal the insert. For the tool to swedge the insert get an old 12point socket put it around the tool and use something like a piece of thin aluminum sheet metal so it fits tightly. Then use an old extension so you can hit it with a hammer.
Note before you install the insert use a hose wrapped with duck tap inserted into the vacuum hose and vacuum out all metal particles.
Remove a valve cover and make sure both valves are closed so you won't get any metal in the valve seat.
They sell kits on ebay for $200.00 to $450.00.
Don't worry take your time if you make a mistake pull the head and take it to a machine shop.

[rhandwor]

This will require a AGSF22WM Motorcraft plug.
A special tool
http://www.autopart.com/TOOLS/TOOLSM...OL/T_98140.htm
These inserts are bored so you use the regular plug.
If you do a search from the link they sell 8 inserts for around $22.00 plus shipping.
The full length insert and plug are for a Triton engine. If another engine measure the insert per the length of plug.

[way2old]

If you drill and tap the head, use grease on the drill bit and the tap and the shavings will stick to the grease and reduce the liklihood of any falling into the cylinder. When the drilling and tapping is done, disable the spark and fuel and crank engine over a few tiom es and this will blow out any small shavings that mah have fell into the cylinder. Good luck. We have done 8 or 10 of these.

[rhandwor]

The reason I specificed Advance is that their tap allows a 3/8 inch extension to fit in the center.
Look at the picture of the specialty unit the tube to turn the tap is thinner than a 3/8 inch drive 19mm craftsman socket. The tap would require a 19mm or 3/4 inch socket. Clearence problems at this point.
I also think you should use greese I use it even to fix small problems.
These taps have a reamer on the bottom no drilling is needed. It would take a 9/16 bit with a 1/2 inch drive. Which would be around $20.00 at Home Depot.
Diffferent inserts take different sizes. He probably is using a Lisle or OTC kit more expensive.
They also make oversize kits if needed.

[rhandwor]

How about telling us how your spark plud insert job went? Did it work out good for you?

[alotech]

Thanks for all the replies. It sounded like it's too much for me to handle on my limited talent. I took the car to one of those neighborhood garages who had it ready for me in about 5 hrs and $160 bucks. Well worth it for me since that 2 hr job would have been 3 days for me and cost even more to repair everything that I broke while working on it. Mechanic gave me several reasons why it happens and he said that he see's it a lot on Ford engines.

[rhandwor]

I think you found the right garage as I've heard some charge close to $2000.00 for a repair.

[way2old]

If you are asking about our replacements, they have been in the vehicles for over 50k and no problems.