I am a fairly handy backyard mechanic. I purchase a 2003 F150 Lariat with a Triton 5.4 about a month ago. Didn't know at the time that this model/year/engine likes to blow spark plugs out of the head. As luck would have it, this happened to me last night. The plug is completely in tact, so I am expecting the thread on the head to be completely stripped (haven't had a chance to look at it thoroughly yet). I have read there are some rethread and Heli coil kits available online to fix this issue. Has anyone had any luck with these? I have never done this before but am very handy and do most of my own work on my vehicles. The shop I have used in the past is estimating 300-500 to do a Heli coil. Any advice anyone could provide would be appreciated. Also is there anything that can be done to prevent this with the remaining cylinders?

 

check the threads, first, I have seen some people get lucky and they arent trashed. It kinda depends on how much they rattled around in there.

imho, 300-500 for one helicoil is high, i would call around. A helicoil will work but isn't the best option as it has no mechanical means of preventing the insert from coming back out. I would be looking into time cert, lock n stitch and there's one other Im drawing a blank on. There are videos on how to do this yourself and places you can rent the kit. The inserts themselves arent too expensive its the tools to install them. Grease the tap/bit and keep cleaning/regreasing and and blow out the cylinder afterward for any shavings.

a plug preparing for liftoff will typically sound like an exhaust leak as an early warning.

Replace the rest of the plugs, torque to spec and do NOT put anything on the threads. Copper plugs are relatively cheap, replace em every year or two and doubt you have any further issues

 

First only use the correct motorcraft plugs they are Platinum, and they have nickel plating for anti-seize on the threads. They are 100,000 mi plugs. Don't add anything to the plugs.

The engines don't like to throw plugs unless they're not torqued right. Seems 100,000 miles is a long time to leave a plug without putting a wrench on it.. especially with low torque.... So they tend to work themselves loose over time when adjusted to the factory torque spec of...11 ft lb. When you stop laughing at that ridiculously low number....torque them to 28 ft lb and you will never have a problem.

I've had other engines throw a plug, Toyota in fact

Unfortunately if you need a thread repair there's only certain thread repairs that are worth a darn and should be used. And the kits for them will cost you several hundred dollars. I think the ones available are Cal van or time sert. Ford put out a TSB at one time to use lock -n- stitch. Don't use anything cheap from AutoZone or helicoil or you'll be redoing it.... Seriously, those inserts do not lock into place. They will come out just like the spark plug did.

 

^^^ cal van is the one I was blanking on

 

A helicoil is doomed to fail.

Use either a Calvan/Snapon, a Lock 'n Stitch, or a Timesert for a permanent repair. If your shop is suggesting anything else, find a new shop.

Re-torque as mbb suggested.

 

Has anyone been able to PROVE that's it's the faulty design of the HEADS? I heard it's a problem with all of the years 1997-2003....I don't believe it. Bought my 97 new and have NEVER had a problem and my 2000 does not have any issues as well. I think people are CROSS THREADING the plug weakening the aluminum threads causing the blow out. What I do is first clean the HOLE out by vacuum then turn the plug left-hand until I feel the first thread click, then turn right hand. Hand tightening only. Never had one to come loose.
If I cared about the truck and expect to keep it for a long time, I would pull the heads and take them to a machine shop and have a head job along with the threads fixed. I just had my heads done on my 2000 5.4 and it was about $350 for everything....threads looked like new( I removed the heads myself). I don't see how they can cut new threads without having shavings in the cylinder....but that's me.
Is the motor leaking oil all over? Does it burn oil? How many miles on it?

 

It would have been nice to add what engine it is?
Knock on wood my 1999 4.2 has not blown out any plugs.

 

Ed, I think the spark plug problems were confined to the modular V8s, and our 6-banger Essex 4.2s were not affected. The Essex v-6 started as a 3.8 liter in 1982, and with some variations (including increasing size to 4.2) it was around until about 2007. A Tried, Tested, and True engine (with due respect to the old Chevy slogan).

 

He said it's a 5.4

 

It's not a faulty head design it's just a low torque spec. Ridiculously low really. Possibly because there's only four or five threads there..... But if you just tighten it to a tighter torque of 28 lb you will have zero problems. As to why they chose that torque spec who the hell knows..... The aluminum threads can take 10 times that. The low torque combined with long life plugs that never have to be checked and gapped...... Means they are left in place untouched for years and years. Totally forgotten about until one loosens and pops out. Oh yeah you've got to ignore the exhaust leak type sound for a long time too before it finally comes out. So in a way it's still operator error

Same thing happened on a Toyota I had.... I had several exhaust leaks where it the exhaust system had corroded through so I ignored the sound... Until bang. I didn't blame Toyota or the head design.....