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Ford Engines - Spark Plug Defect

rick of johnston, RI July 3, 2009

spark plugs blew out of the heads do to poor design!! apparently ford choose not to use steel inserts for the spark plugs to screw into so this means that they are threaded into the alluminum head which is not strong enough to hold the plugs in. this causes the threads to become stripped and forces the plugs to be pushed or blown out of the heads like bullets causing major damage and a very expencive fix and this is for all 4.6 engines and up from about 97 to 2003!!! this should be a recall so why isnt it? just google "spark plug blowout ford" you will see. almost crashed my truck and cost alot of money to fix. also caused damage to other parts of the truck and almost caught fire!!

Alfred of Roseville, CA July 2, 2009

I have a 1999 Ford Expedition. It has 142,000 miles on it. One of the spark plugs ejected and there are no longer any threds in the head. My local Ford dealer has told me that Ford is aware of the issue but it is my fault for not periodically tightening down the spark plugs. Most of the plugs are not even able to be reached by human hands and I have looked all through the owners manual and I don't see any such suggestion. The dealer told me to replace or remanufacture the head, which would cost more than the car is worth, or he has a technician that could re-thread the stripped hole but there would be no guarantee. I not only feel that this an obvious design flaw, I also feel that Ford has known about this occuring for over ten years. They don't need to do a recall but they should foot the bill to replace the heads when it happens.

Joe of Moores Hill, IN June 24, 2009

I own a 2004 f-150 that has experienced the seized spark plug problem and several of the plugs have broken inside the head. My mechanic has gotten two of the three out but has had my truck for over a week. He has even tried to fabricate tools to solve the problem after trying the removal kit without sucess. Ford will do nothing to help me with the problem.

STEVEN of WEBSTER, MA June 20, 2009

We have a 2002 Ford Windstar with 62000 miles on it. My wife backed out of the garage and heard something rubbing when she turned the wheel. She drove it back in the garage. I found that the left front coil spring had broken. Luckily it had not punctured the tire.

Larry of Livermore, CA June 20, 2009

June 19,2009 while driving my 2001 F250 V10, it spit a plug. Plug is on passenger side, rear cylinger. This is a recurring problem with the ford motor and a health and safety issue. Fuel from the injector and spark from the coil can cause a fire, either injuring or killing passangers. For is aware of the problem, but refuses to do anything about it. Something needs to be done about this issue

Lisa of Avondale, AZ June 20, 2009

A week or so ago I heard a minimal tapping. I scheduled for an oil change, etc but before I could make the appointment I started it and heard BAM BAM BAM BAM under the hood. Popped the hood to see a spark plug popping around. So I Google, "spark plug blew out" and what comes up- my exact make and model, a 2001 Ford Expedition with a Triton! This is ridiculous. What does it take to start a recall, a death from a fiery crash? RECALL!!

Billie of Lompoc, CA June 19, 2009

I have a ford expedition that had a spark blow up. I had a insert put in and was told it was fixed well it blew out again so now it has been parked for one year. Ford just does not care.

I was left stranded 3 1/2 hours from home with my son in a wheelchair we were stuck for 5 hrs. on the side of the road.

Perry of Jupiter, FL June 15, 2009

My 2003 Ford Expedition spit a spark plug on 6-14-09 in Lakeland, FL. I live 200 miles away from there. Had to abandon the car there til Monday when something was opened. This looks costly and is going to cost me dearly in time and money

Tim of Kutztown, PA June 15, 2009

i have an ford van ,E 350 with a v10 engine ...it just blew out #3 spark plug. i do mechanic work and i don`t see any way of fixing this without removing the engine. van has only 71,000 miles

Theodore of Atlanta, GA June 13, 2009

I have a 2003 Ford Expedition Eddie Bauer Edition with 117,788 miles. My wife and five boys were out shopping for groceries Thursday and Irecieved a call stating that she heard a loud pop under the hood. They were able to make it home. Once I arrvied home from work I investigated under the hood to discover the second spark plug from the front on the passenger side blow out of head. I am glad the truck did not catch on fire with my wife, 18 month, 3, 8, 10 and 11 year old sons. I am finding through research that Ford and NHTSA are aware of the problem but it is not covered under warranty.

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