really awful
Crashes / Fires:
0 / 6
Injuries / Deaths:
0 / 0
Average Mileage:
99,168 miles

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« Read the previous 20 complaints

problem #40

May 082009


  • 138,000 miles
Vehicle was in the drive way and caught on fire burned completely up and blew out tires. There is a report with the fire department.

- Acworth, GA, USA

problem #39

Jan 012008


  • 70,000 miles
The contact owns a 2002 Ford F150. While driving approximately 60 mph, the driver suddenly heard a loud noise coming from the engine compartment. She initially thought that the muffler failed. The vehicle did not stall or overheat. She drove the vehicle to a mechanic, who stated that a spark plug blew out due to the aluminum head on the engine. The mechanic performed a healie core and replaced the plug. The vehicle drove normally for over a year before the failure recurred. While driving 65 mph, the contact heard a popping noise coming from the engine. She drove approximately one mile and then had the vehicle towed to the Ford dealer. The mechanic stated that the vehicle had a defective cylinder, which caused it to blow out the spark plugs. The mechanic further stated that it was a very common issue and no recall was available. The contact is waiting for a call back from a Ford supervisor. She believes that Ford should be responsible for the repair. The vehicle has not yet been repaired. The failure mileage was 70,000 and current mileage was 98,000.

- Palmdale, CA, USA

problem #38

Apr 122009


  • 117,000 miles
Leading up to the spark plug being blown out of my Ford F-150 with a 5.4 L motor, I heard a distinct ticking sound that resembled an exhaust manifold leak. Driving on the highway around 75 miles per hour, two hours into my drive the tick became louder and finally a pop came from under the hood. I then pulled over and left the truck idling. Looking under the hood I see the coil over pack vibrating a lot and then I shut the truck off and unplugged the coil over pack and out came the coil over pack and attached a spark plug. The coil over pack was broken due to the force of the plug being blown out. I am now in the process of towing my truck home which is 3 hours to do the repair necessary to fix the problem. To fix the problem I am looking to install a thread insert in hopes of saving a lot of money. This is the cheaper easier way to fix it for I do not want to replace the head myself nor do I want Ford's investing thousands to replace it.

- Romeo, MI, USA

problem #37

Feb 202009

F-150 8-cyl

  • 55,000 miles
2002 Ford F-150 w/ 5.4 L V-8 engine----spark plugs keep blowing out of engine.

- Reisterstown, MD, USA

problem #36

Feb 132009


  • 100,000 miles
My 2002 Ford F-150 blew a spark plug right out of the cylinder while driving on rt 85 in Connecticut. The danger from this was great as there was gas splashed throughout the engine compartment. Went T the Ford dealer and they played down the situation and said it would cost $600 to fix. I also incurred a $200 towing bill, and had to replaced a spark plug coil which was damaged by the spark plug to the tune of $100. The internet has provided information that this is a significant problem with Ford V-8 engines, and I'm wondering why the NHTSA lets this continue...many people are suffering financial loss, and safety issues with fires that result from this situation.

- Colchester, CT, USA

problem #35

Feb 102009


  • 86,462 miles
I own a 2002 Ford F-150 XLT 4X4 with a trition 5.4L V-8. I went out to start it this morning and I heard a loud noise that sounded like a shot went off. Then my truck started shaking and making a chugging noise. I shut it off and opened the hood and found that one of my spark plugs just blew out of the engine. It broke the coil and stripped out the threads where the spark plug goes. I had to have it towed to a mechanic and it cost $503.83 for the repair. The mechanic told me this was a common problem with the trition engines. I went online and did some research and found many complaints of the same subject. I think Ford needs to issue a recall to fix this problem.

- Port Hueneme, CA, USA

problem #34

Jan 232009


  • 119,000 miles
On my birth day I experienced something like never before I blew the #4 spark plug on the passenger side brought it back to work what a rough ride. Then started to look in the hole with a bore scope to find out the treads were gone yeah. Called around to find out how much it would cost me and the cheapest was a machine shop called lentech automotive at a price of $300 not bad but I made some more calls and found a kit to do it at bensons autoparts $65 hope this will fix it.

- Gatineau, 00, USA

problem #33

Dec 122008


  • 116,000 miles
I experienced a spark plug blow out on my way to work. I was stranded on a narrow road and had to call for help. My dad called a tow tru ck and we had it towed to the dealer in kailua kona, Hawaii. We saw that a spark plug had blown out. The tow truck driver said his truck did the same thing. At the dealer they said they did not know why it did that. After getting it repaired for $600, my truck would not run. They said, you need a new engine at the tune of $5,000. It ran fine prior to that spark plug blow out. With further investigation, an expert mechanic suspects they mishandeled the installation. They want me to pay for their mistake. This started out a Ford part defect, but is ending up a destroyed engine. I will demand they fix it, or we will sue. This is outrageous!!! Ford should not be bailed out. Why can't someone do something about this" jail, perhaps" I am without a truck.

- Kailua Kona, HI, USA

problem #32

Nov 262008


  • 162,524 miles
I was driving to pick up lunch one day from work and when I pulled out into traffic to head back I heard a loud pop followed by a loss of power and a sound that made me think the serpentine belt broke. The plug shot out of the head and broke a coil pack in half. I talked to the Ford dealer that I get my parts at, and he told me it happens alot on 4.6 liters, 5.4 liters, and V-10 Ford trucks so much that they stay well stocked on the parts that I needed to fix what Ford doesn't consider to be a problem, the fix is a well greased, extra long 14 mm tap and helicoil, red locktite, spark plug, coil pack, and any other bits and pieces the plug destoys on its way out, from the reports I'm reading I got lucky thtat it was just my coil that took the brunt of it, I've talked to some people around the area and they see any where from 2 to 4 per week, and on top of that there was two people at my work that have had the same problem. We only have 18 employees. One was in a 5.4 and the other was a V10. The dealer told me there was no recall on the problem and that Ford doesn't recognize it. The part will be repared and will not be avalible and just cost me more of my time and money doing stupid repares that are questionable at best.

- Temperance , MI, USA

problem #31

Oct 042008


  • 79,000 miles
Twice within one year, on two different occasion, my 2002 F150 Ford truck has ejected a spark plug. There was no indication that there was an issue leading up to the event occurring. Both times I had my truck towed to my local Ford dealership and repaired. The repair both times consisted of the instillation of a heli coil and the bill was around $700.

- Placerville, CA, USA

problem #30

Sep 102008


  • 90,000 miles
Purchased used 2002 F-150 lariat with 80K miles in 4/08. Sept 9th the spark plug #6 blew out of engine. Not covered under warranty. Had to tap and placed helicoil to fix. Oct 10th the spark plug #8 blew out of engine. Current mileage is 90K.

- Wichita, KS, USA

problem #29

Oct 032007


  • 100,000 miles
Spark plug blow out in 2002 Ford F150. Spark plugs blow out and fuel vapor seeps out. No fire on my car, but very well could be. Known problem Ford refuses to recall. Jack

- Smithville, MO, USA

problem #28

Sep 132008


  • 114,000 miles
Started off from stop sign and around 30-35 mph, heard a loud popping sound and pulled over to find #3 cylinder had blown spark plug out. Coil was damaged also. Had truck towed to nearest shop 40 miles away.

- Lincolnton, GA, USA

problem #27

Aug 162008


  • 138,000 miles
While driving down the road, I heard a loud explosion and the engine began running rough. I pulled over and opened the hood. The explosion had dented the inside of the hood. I found a broken coil laying on top of the engine, and the corresponding spark plug laying beneath the engine. I took the vehicle to a mechanic, who re-threaded the spark plug hole and installed a new spark plug. The vehicle performed as usual for about six months, and then the same exact situation occurred, involving the same exact spark plug. The second occurrence, the plug and coil were so damaged that the head could not be re-threaded and repaired. After researching this issue, I found that dozens of other owners have experienced the same problem, which is due to an engine and/or piston defect. The second occurrence required drilling out the affected head, tapping it, and installing a helicoil before the spark plug could be replaced. I am very concerned about this issue, since in addition to the expense and inconvenience this manufacturing defect has caused me, it is extremely dangerous as well. While I have not had an engine fire, other owners of this make and model have reported engine fires.

- Clarksville, TN, USA

problem #26

Aug 172008


  • 51,581 miles
I have a '02 Ford F150 with 51,581 miles on it. Yesterday, cylinder #3 decided to blow the spark plug right out of the cylinder head. Fortunately, I was able to stop the vehicle immediately. After reading many other frustrated customers with the same issue, I found out that I was quite lucky that the engine didn't immediately erupt in flames. Ford refuses to acknowledge there is any issue with this design even though it's well documented. Ford expects it's customer to replace the head to resolve the problem at the customer's expense. Mine $3,322.96. Now the better part. Because it appears the design has not changed, even by replacing the head there is no guarantee that this will not happen again.

- Greenfield, MN, USA

problem #25

Aug 102008


  • 42,009 miles
My 2002 Ford F150 5.4 spark plug blow out of the motor with only 42000. Miles on it. $ $890 to repair.

- Benicia, CA, USA

problem #24

Jul 122008


  • 69,000 miles
I was driving and felt and heard a pop in the engine compartment. I pulled off the road thinking it was a tire blow out. Once I got out and checked the tires I started the engine again. It sounded like there was no exhaust manifold. I had to get it towed to a service station. I later found out that it blew out a spark plug out of the head and split the coil and possibly damaged another coil. It has not been repaired yet. I am very dissatisfied with the situation. I have done research and found thousands and thousands of other people having the same problem. Owners of these vehicles should not have to pay out thousands of dollars for a Ford design error.

- Roseville, CA, USA

problem #23

May 202008

F-150 8-cyl

  • 50,000 miles
The contact owns a 2002 Ford F150. The contact stated that the sparks plugs were loosening and stripping off the treads. The spark plugs were also detaching from the vehicle. He notified the Ford dealer and they stated that there was nothing wrong with the spark plugs flying off the vehicle. When the spark plugs detach, sparks fly. The failure occurs whenever the vehicle is started and before moving. The failure always occurs with the number three cylinder. The failure mileage was 50,000. Updated 07/29/08. Updated 08/05/08.

- West Caldwell, NJ, USA

problem #22

May 312007


  • 143,000 miles
The contact owns a 2002 Ford F150 harley davidson. On January 3, 2008, a spark plug blew out. On May 31, 2008, while at a car wash, the contact heard a loud noise. The vehicle was turned off and towed to the dealer. The dealer stated that the same spark plug from the solenoid had blown again, which also blew the engine head. The repair is expected to cost between $2,200, and $5,000. Also, in December of 2007, the sunroof motor shorted and no longer works. She was informed that the repair would cost $1,000, and has not used the sunroof since. The current and failure mileages were 143,000.

- Fresno, CA, USA

problem #21

Mar 032008

F-150 8-cyl

  • 102,000 miles
Plug blown out of head!!!!!!! cost 250 dollars to fix..........

- Decatur, AL, USA

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