2002 F150, 5.4, approximately 145,000 miles. I had a plug blow out a few years ago, maybe 6, and towed it to the dealership for repair. I went to change plugs yesterday, and no.4 came out very hard, with what looks like about 1 thread worth of an insert. I didn't notice this until I tried to start the new plug in and it won't grab the threads. I ordered a borescope to see if anything is still in the threads, but it won't be here until tomorrow. My concern is if there is still a portion of an insert or helicoil in there, is the head shot? Or will a Cal_van tool ream this out to accept the new insert? The discription for the tool kit says it can repair failed inserts, but before ordering the kit, I wanted to get the opinion of people that have done the repair.

 

It really depends on how messed up it is. I know Time Sert has an oversized kit, which I believe they call "Bigsert". I am not aware of Cal Van having an oversized kit.

My guess is, you need an oversized kit based off your description.

 

Not to be dense, but I can't help it most times. The timesert tool/system, will cut through the insert of it is still in there? Some threads say this must be removed before proceeding, so I'm trying to determine my solution based on what I see when the borescope gets here.

 

It is my understanding, yes, that you'll want all of the previous repair out of there before using the new insert. So your borescope is going to tell you a lot of how it needs to be approached.

It appears you are from SLC? What dealer used a Heli-Coil? Those things are not the correct repair for this application.

 

Ken Garff Ford did the repair. I moved recently and have effectively lost all my paperwork and receipts for my truck, so I can't read the repair order. It may have been more than 6 years ago, I honestly can't remember. I don't know if it's a helicoil or some other type of insert. I'm just hoping I don't have to pull or replace the head at this point.

 

The location in West Valley (formerly Henry Day)? Where are you now? I live in Tooele.

If I were you, I'd get some pics from your borescope and post them. We can help a little better when we can see what you're up against.

 

Yes. I think it was Henry Day when the work was done. I was a caregiver for aged parents and most of the last decade is a blur. I'm in Canyon Rim. I just looked at the plug under a glass and I'm sure there will be remnants in the head. I'll get pictures when I get the scope.

 

Oh cool... my Brother used to live in Milcreek. Small world!

Yeah, post what you find with the borescope. I'm interested to see what you have in there.

 

A picture of the thread might offer a clue. Helicoil wire has a distinctive shape.

 

I didn't get the borescope yet, but here is a picture of the plug with the insert on it. With my glasses on, I see there is more there than I thought.