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Ford Tech- Blown out spark plug


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#1 Drunk Prom Date

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Posted 29 January 2013 - 12:39 PM

So its a know problem with fords to blow the spark plugs out of the heads, break the coil.  

Here is the tool kit required to repair it:
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Very first thing!
It has to be on TDC(Top Dead Center) Compression stroke, its best to have the piston as far down as possible, but coming up on compression stroke so the VALVES are CLOSED!!

I use this tool to somewhat screw back in the head, have someone barely bump it over with all the ignition coils unplugged!  When its on compression stroke, it should blow your thumb off the end of the hose and stop there, hopefully the piston didn't go past TDC.  
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Once that is done, use the tap and the drive tube to start cutting the old threads out and tapping new threads for the insert.


I have a head off another ford product from a blow up engine to show a little better.
Here is the Tap coming through the spark hole
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top view
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what ive done is ran the tap as far as it's needed to go, you dont need to bottom it out.  once the bigger part of the tap started coming through i stopped.
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at this point i scared the drive tool, so i know how for to run the tap in.  after that i chucked it up on the lathe and grooved it so i don"t loose my line.
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#2 Drunk Prom Date

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Posted 29 January 2013 - 12:39 PM

So run the tap into the bad plug hole til you hit your marked line.  here is half way through, you can see the threads starting, and its still tappered at the bottom where its cutting out the old threads.
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Blowing all the dirt and debris out of the spark plug tubes is very important!!!
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once tapped all the way, make sure to clean out all the shavings and debris, you can use air to blow it out or get a vacuum with smaller rubber hose to suck out the shavings from the cylinder.  when your done with that, its time to install the insert
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What i like to do is use vice grips and clamp the threads so it has a better chance of staying in the head when you try and take the tool out, sometimes the insert will get stuck on the tool and unthread from the head.
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Be sure to use lock tight on the insert!
Once its stuck down in the head, you use this tool and hammer, so the insert gets locked against the cylinder head.  It has a little tappered flair the spreads the insert.
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After all that, you have a new spark plug threads that are steel instead of aluminum.  The OE setup has 3-4 threads that holds the plug in place, the steel insert has 5-6 threads.  Not a big step up, but it works. here is the insert locked in place once your done.
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#3 Phantom 309

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Posted 29 January 2013 - 01:01 PM

I get scared of this every time I think I hear something new from Shannon's V10.

#4 Drunk Prom Date

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Posted 29 January 2013 - 01:06 PM

Its fixable...   posted it all up just for you! :thumbup:

#5 snyder

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Posted 29 January 2013 - 01:22 PM

Is this a problem with the 03 5.4 as well?
:unsure:

#6 Drunk Prom Date

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Posted 29 January 2013 - 02:52 PM

Yes, the 03 has the same problem.  

Be thankful you dont have the 2004 year model, i think they have a much worse design.  

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This newer plug design they use will get stuck in the head, instead of blowing out...


#7 ChevyJoe

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Posted 29 January 2013 - 05:02 PM

My 06 f150 has the 5.4. How many miles before this happens?

#8 Floorit

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Posted 29 January 2013 - 05:35 PM

View PostChevyJoe, on 29 January 2013 - 05:02 PM, said:

My 06 f150 has the 5.4. How many miles before this happens?

Do you even own any Chevys any more? I'm changing your name to FordJeepJoe.

#9 ChevyJoe

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Posted 29 January 2013 - 06:30 PM

Haha nothing I currently own has a Chevy motor

#10 Drunk Prom Date

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Posted 29 January 2013 - 10:06 PM

View PostChevyJoe, on 29 January 2013 - 05:02 PM, said:

My 06 f150 has the 5.4. How many miles before this happens?

You want to change plugs before 100k miles..  The more carbon build up between the head and the bottom part of the spark plug... the chances of it breaking off are higher.  

The last ford i worked on that had those plugs and had over 100k miles, i let the fuel injection flush machine run on the truck for a good hour before i attempted to even take a plug out.  I had no problems doing it that way.

#11 snyder

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Posted 30 January 2013 - 07:57 AM

Mine just hit 100k. Great :wacko:

#12 Phantom 309

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Posted 30 January 2013 - 09:20 AM

MIne's at 110K.


Do the coil packs need to be replaced at the same time? On the Excursions, does the body have to be lifted to get the back two?

#13 Phantom 309

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Posted 30 January 2013 - 09:20 AM

I hate you for posting this thread, Jake. :2guns:

#14 snyder

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Posted 30 January 2013 - 09:36 AM

Mines in a navigator,  looks like it'll be a real sumbitch

#15 Drunk Prom Date

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Posted 30 January 2013 - 12:04 PM

View Postsnyder, on 30 January 2013 - 09:36 AM, said:

Mines in a navigator,  looks like it'll be a real sumbitch

yes! especially with rear heat, it definitely makes it a lot harder to do.  But i have done one... and i hated every minute of it

#16 Drunk Prom Date

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Posted 30 January 2013 - 12:06 PM

View PostPhantom 309, on 30 January 2013 - 09:20 AM, said:

MIne's at 110K.


Do the coil packs need to be replaced at the same time? On the Excursions, does the body have to be lifted to get the back two?

I would advise coils, they are known to short out and cause intermittent miss fire problems unload when hot.  But Its your call whether you do it or not.

No body lifting, just have to crawl back there and get them out.

#17 snyder

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Posted 30 January 2013 - 01:27 PM

Well thanks for the info DPD . I'm going to drive it into the river now

#18 waycrazy

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Posted 30 January 2013 - 10:45 PM

Just a FYI I have a set of 5.4 heads if anyone ever has a problem. I destroyed a cyl. wall and melted a piston but the heads were still in excellent shape . I ended up getting another engine and saved the heads from the old one.
On a different note I am waiting for Phantom to fubar the engine in his excursion so I can pick it up cheap. :laughing:  A Cummins Diesel swap seems like a good idea!

#19 snyder

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Posted 31 January 2013 - 05:58 AM

View Postwaycrazy, on 30 January 2013 - 10:45 PM, said:

Just a FYI I have a set of 5.4 heads if anyone ever has a problem. I destroyed a cyl. wall and melted a piston but the heads were still in excellent shape . I ended up getting another engine and saved the heads from the old one.
On a different note I am waiting for Phantom to fubar the engine in his excursion so I can pick it up cheap. :laughing:  A Cummins Diesel swap seems like a good idea!

I'd like to find a diesel excursion,  but the ol 7.3  . Trying to find one with less than 100k on it is difficult since 02/03 was the end of that era .

#20 Drunk Prom Date

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Posted 31 January 2013 - 12:35 PM

View Postsnyder, on 31 January 2013 - 05:58 AM, said:

I'd like to find a diesel excursion,  but the ol 7.3  . Trying to find one with less than 100k on it is difficult since 02/03 was the end of that era .

You don't want a 6.0 Diesel?  :rofl:

#21 kfinney

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Posted 31 January 2013 - 01:11 PM

We have an 01 Excursion....ours blew out at 70,000.  Made a terrible noise.  If you think you hear an exhaust leak, check it right away.  

#22 Drunk Prom Date

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Posted 31 January 2013 - 03:18 PM

View Postkfinney, on 31 January 2013 - 01:11 PM, said:

We have an 01 Excursion....ours blew out at 70,000.  Made a terrible noise.  If you think you hear an exhaust leak, check it right away.  

Yes, they are all sorts of loud!

#23 GreenGo80

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Posted 31 January 2013 - 03:33 PM

A cummins conversion would be the best thing to happen to any ford haha. Especially a 6.0.

#24 Drunk Prom Date

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Posted 31 January 2013 - 04:08 PM

Hell with that, i wouldn't make any money if they did that...

#25 gregj50

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Posted 10 March 2013 - 04:04 PM

Happened in my 08 work van!! Just turned 100,000! The shop said i needed new heads.....$4000.00 later!! They said the reamer inserts dont work all the time! I havnt heard anyone say they have had em blowout though!!