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Spark plug ejected Ford 5.4 #4117292 06/06/16 08:54 PM
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Run Offline OP
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This is the first time I had such an experience. I was driving a 99 F250 when it just went BANG! I was surprised the engine didn't stall. Somehow I made it back to the shop. How much damage did I cause by driving it like that? It was just over 2 miles in city traffic. Only 1 plug lost and coil destroyed, boy did that truck run poorly.


09 Hyundai Tucson 2.0 5spd
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117297 06/06/16 09:07 PM
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Danno Offline
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Engine should be OK, get a couple of quotes if possible. Should be repairable without pulling the head.


2019 Jeep Grand Cherokee Summit 5.7L Hemi
2019 RAV4 Limited Hybrid
2016 Sorento SX V6 AWD
2010 Mazda 3 2.0L
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117300 06/06/16 09:10 PM
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Rand Offline
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http://castingrepair.locknstitch.com/viewitems/spark-plug-hole-thread-inserts/ir-insert-kits-for-ford-modular-and-triton-engines?&bc=100|1002|1006

IIRC thats the Ford preferred repair method (dealer authorized)

http://www.locknstitch.com/pdf/Sparkplug%2014mm%20insert%20instructions.pdf


2019 Jeep Cherokee Trailhawk 2.0T
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117350 06/06/16 10:29 PM
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MNgopher Offline
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Well, the bad news is its a relatively common issue.

Which means the good news is it is repairable and there are reputable repairs for it - as identified in the post above.

Honestly probably didn't do any additional damage to the engine.

Re: Spark plug ejected Ford 5.4 [Re: Run] #4117357 06/06/16 10:49 PM
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Kruse Offline
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USUALLY, you will just need to pay for the insert repair (labor, insert) and the cost of a new coil.

Re: Spark plug ejected Ford 5.4 [Re: Run] #4117363 06/06/16 11:21 PM
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901Memphis Offline
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Isn't that pretty bad for the cat getting fuel into it?


2012 Chevy Cruze LT 1.4T - 62k - Edge 0w30 SL + Mahle OX401D
2002 Buick Century 147k - Built 4T65e(Maxlife) - GTX 5w30 + Fram XG3980
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117380 06/07/16 12:13 AM
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NavyVet88 Offline
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What do you guys mean by "IIRC"?


2013 Honda Civic LX 1.8L 178k M1 HM 0w20 with Fram XG7317
2002 Ford Ranger Edge 3.0L 67k Castrol Edge 5w30 with Fram XG3600
Maintenance Technician by trade, working class for life.
Re: Spark plug ejected Ford 5.4 [Re: NavyVet88] #4117385 06/07/16 12:31 AM
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tomcat27 Offline
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Originally Posted By: NavyVet88
What do you guys mean by "IIRC"?

If I recall correctly


2019 Cherokee, 2018 Jetta, 2014 Sentra, 2001 Camry, 1995 Escort, 1970 Cougar, 2013 XT250, 2010 Vstar, 2014 CTX1300
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117386 06/07/16 12:32 AM
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bdcardinal Offline
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IIRC = If I Recall Correctly


2014 Ford Mustang GT Track Pack
1995 Ford Mustang GT

Ford/Mazda Parts Counter
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Opinions expressed are my own.
Re: Spark plug ejected Ford 5.4 [Re: 901Memphis] #4117392 06/07/16 12:45 AM
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Originally Posted By: 901Memphis
Isn't that pretty bad for the cat getting fuel into it?


The PCM will detect the severe misfire and cut off the injector for 30 seconds at a time. Then it turns it back on for 200 revolutions of the engine before shutting it off again.

Short-term (a few miles) this will prevent the cat getting too hot. If you have to drive it longer, I recommend unplugging the injector. I drove my CVPI 160 miles with a blown out plug by unplugging the injector.

Oh, and unplugging the MAF helps get some of the power back too. My educated guess is with a cylinder drawing air from the plug hole, its way under representing the load on the engine. Letting it use the Failed MAF table in the PCM is a little closer to reality.


-Colton
2002 Ford Crown Vic PI 207k, Ex-Kootenai County, ID Unit #42
Down for engine swap
2003 Ford Crown Vic PI 86k
Pennzoil Conv HM 5W30, Fram XG2
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117432 06/07/16 04:53 AM
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pbm Offline
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What exactly causes this to happen? Is it just that there are too few threads in the engine? Are these repairs permanent?


'Journalism is Dead'
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117452 06/07/16 06:11 AM
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Low thread count along with low torque value (as a result of the lack of threads). What Ive experienced is the plug working loose over time for whatever reason. Probably expansion and contraction.

The reason I know this, is the day before mine blew, I heard a ticking while I was in a drive through. My window was open and I was hearing the sound reflect off the wall. It was too light to hear otherwise.
The ticking was the plug leaking as it had come loose. I changed the plugs on a friend's F150 with the same engine and it had a plug that was loose too. The coil pack boot was totally cooked.
The difference is his engine was a 2005, so it had the updated '8-thread' heads and it survived this until I replaced it.
Take a 4-thread head and loosen the plug a turn and you get a time bomb.
There is a place advising using a very high torque value on the spark plugs to prevent them from loosening, but, Ive checked and the stock value of 10ftlbs is about all you want to give a 4-thread head. Taking into account the strength of the cast aluminium.
An 8 thread head is much better in that respect, and 18-22ft-lbs is doable. So, I did tighten the plugs on the F150 to 18ft-lbs.

The repair is pretty much permanent. It converts it to an 8-thread hole, so barring spark plug installation error at some point, its permanent.


-Colton
2002 Ford Crown Vic PI 207k, Ex-Kootenai County, ID Unit #42
Down for engine swap
2003 Ford Crown Vic PI 86k
Pennzoil Conv HM 5W30, Fram XG2
Re: Spark plug ejected Ford 5.4 [Re: Run] #4117454 06/07/16 06:18 AM
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Miller88 Offline
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I drove one of these >100 miles with a dead coil. Didn't seem to care and certainly didn't destroy the catalyst.


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01 F-350 4x4 5M
Re: Spark plug ejected Ford 5.4 [Re: Rand] #4117503 06/07/16 07:29 AM
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Trav Offline
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Originally Posted By: Rand
http://castingrepair.locknstitch.com/viewitems/spark-plug-hole-thread-inserts/ir-insert-kits-for-ford-modular-and-triton-engines?&bc=100|1002|1006

IIRC thats the Ford preferred repair method (dealer authorized)

http://www.locknstitch.com/pdf/Sparkplug%2014mm%20insert%20instructions.pdf


+1 The LOCK-N-STITCH is the only correct method of repairing the threads on these engines. Messing around with Heli Coils just ruins the head and should never be used.
The Heli Coil presents 4 problems, without the bushing it is impossible to get the reamer and tap dead straight in the bore, it does not transfer heat properly away from the plug in the aluminum head, the seat is not correct for the plug and can leak and the tang that gets broken off in the coil is steel and can damage the cylinder.

This repair should only be done by a pro with the LOCK-N-STITCH tools and experience using it or the dealer, this is a one shot deal there is no redo.


ASE L1, Master. Deutsch Meisterbrief.
Re: Spark plug ejected Ford 5.4 [Re: pbm] #4117543 06/07/16 08:33 AM
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RF Overlord Offline
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Originally Posted By: pbm
What exactly causes this to happen? Is it just that there are too few threads in the engine? Are these repairs permanent?
Aside from the too-few threads, the primary reason for launching a spark plug in a modular motor is people who think they don't need to use a torque wrench causing damage to the threads by over-tightening. The factory spec is 11 ft-lbs, no anti-seize.


Supercharged '03 Mercury Marauder - Trilogy Motorsports #61
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