Blown out sparkplug

[BlackCoffee]

If I remember my head correctly, there are no threads at the top of the spark plug hole. There are only a few threads near the bottom and that is why the plugs tend to blow out. It is also why the helicoil that threads more of the hole is a stronger fix. My bet is that putting in the helicoil will thread enough of the hole to be fine. It looks like it caught the top edge coming out.

 

[TobyU]

If I remember my head correctly, there are no threads at the top of the spark plug hole. There are only a few threads near the bottom and that is why the plugs tend to blow out. It is also why the helicoil that threads more of the hole is a stronger fix. My bet is that putting in the helicoil will thread enough of the hole to be fine. It looks like it caught the top edge coming out.

I think a thread insert will work fine but just remember why everyone says not to use Helicoil and to use an insert that is solid like a Time-Sert. The Hrli coils are just a spiral round of spring and the threaded solid insert is much thicker and makes it more solid like the original hole that was tapped.

 

[BlackCoffee]

I think a thread insert will work fine but just remember why everyone says not to use Helicoil and to use an insert that is solid like a Time-Sert. The Hrli coils are just a spiral round of spring and the threaded solid insert is much thicker and makes it more solid like the original hole that was tapped.

I agree, the inserts are better. I don't know what Ford was thinking on these heads. The spark plugs holes are a mess, and the entire cam setup, no bearings and attached cam sprocket was a mistake as well. All I can think is that going to aluminum heads had them confused. At least they got rid of the integrated sprocket in gen 3.

 

[Boostedbus]

Wow good luck with the thread-sert and hope it works for you. I just dodged a bullet on my 5.4 2v Utility Van today. I decided to change the plugs since I’ve got some time and thought I’ve been hearing a very faint exhaust leak. I changed The original plugs at 70,000 miles and I only have 122,000 miles now. But knowing how they are prone to loosen up I thought I’d rather be safe than sorry with 52,000 miles on this set instead of waiting until 70,000 miles. I’m glad I did! #2 cylinder boot was burnt and the plug was loose enough for me to spin it out with my fingers. It’s not real easy putting plugs in the E series vans with these big modular engines but well worth not waiting until the scheduled 100,000 mile plug change. It’s too risky in my opinion. I installed the last set and I am known for over tightening and snapping things off from putting Hercules torque on everything, and I still had one loosen up. I also remember when I changed the originals at 70,000 miles I had a couple plugs that were barely snug at best. Check out the set on the left.

 

[Hamfisted]

Boostedbus hats off to you ! I take back everything I ever said about plug changes on my Expy ....

Wow good luck with the thread-sert and hope it works for you. I just dodged a bullet on my 5.4 2v Utility Van today. I decided to change the plugs since I’ve got some time and thought I’ve been hearing a very faint exhaust leak. I changed The original plugs at 70,000 miles and I only have 122,000 miles now. But knowing how they are prone to loosen up I thought I’d rather be safe than sorry with 52,000 miles on this set instead of waiting until 70,000 miles. I’m glad I did! #2 cylinder boot was burnt and the plug was loose enough for me to spin it out with my fingers. It’s not real easy putting plugs in the E series vans with these big modular engines but well worth not waiting until the scheduled 100,000 mile plug change. It’s too risky in my opinion. I installed the last set and I am known for over tightening and snapping things off from putting Hercules torque on everything, and I still had one loosen up. I also remember when I changed the originals at 70,000 miles I had a couple plugs that were barely snug at best. Check out the set on the left.

 

[Boostedbus]

Boostedbus hats off to you ! I take back everything I ever said about plug changes on my Expy ....

Yeah I’m starting to get it down pat. A few months back I did the plugs on my father’s 06 5.4 E250 because he had a bad coil at about 52,000 mi. Once the doghouse is off and the air box and hoses, PCV lines, trans dip stick bracket ,and all coil and injector plugs are unplugged and out of the way then you can feel your way through it. It took me 4hrs. start to finish.

 

[TobyU]

View attachment 35533 View attachment 35531 Wow good luck with the thread-sert and hope it works for you. I just dodged a bullet on my 5.4 2v Utility Van today. I decided to change the plugs since I’ve got some time and thought I’ve been hearing a very faint exhaust leak. I changed The original plugs at 70,000 miles and I only have 122,000 miles now. But knowing how they are prone to loosen up I thought I’d rather be safe than sorry with 52,000 miles on this set instead of waiting until 70,000 miles. I’m glad I did! #2 cylinder boot was burnt and the plug was loose enough for me to spin it out with my fingers. It’s not real easy putting plugs in the E series vans with these big modular engines but well worth not waiting until the scheduled 100,000 mile plug change. It’s too risky in my opinion. I installed the last set and I am known for over tightening and snapping things off from putting Hercules torque on everything, and I still had one loosen up. I also remember when I changed the originals at 70,000 miles I had a couple plugs that were barely snug at best. Check out the set on the left.View attachment 35531

I did a 97 E-Super Duty V10 once and it does suck.

 

[Boostedbus]

I did a 97 E-Super Duty V10 once and it does suck.

I put a reman engine in a 86 E250 we had way back. That was a piece of cake being it was a 302W. That little mill fit comfortably under the dashboard.