I was driving my Excursion around 25 mph and as I accelerated to 35 mph I heard a loud bang and thought my exhaust manifold may have cracked or came loose. After further investigation I found the spark plug wire and spark plug were blown out. Called local mechanic and said I needed to bring it to Ford for approx 4K, Ford would replace the head. I went on line and purchased a kit, Ford is aware of the problem with the spark plug being blown out of the head but will not recall the truck. Note that this is affecting many vehicles, not only Ford. This is a huge issue and very unfair that the manufacturer of the head is getting away with the poor quality control and the fact that they are not correcting the issue for the consumer.

- Morisstown, NJ, USA

Recently had #2 spark plug blow out of my Excursion.

- Waurika, OK, USA

Spark plug blow off.

- High Point, NC, USA

The contact owns a 2000 Ford Excursion. The contact stated that her vehicle caught fire while it was parked. The fire was under the drivers side wheel and then the entire engine was engulfed in flames. The fire department extinguished the fire. A fire report is available. An insurance adjuster will inspect the damages. The cause of the fire was unknown. There were no injuries. The manufacturer has not been notified. The VIN was unknown. The failure mileage was 100,000.

- Annapolis, MD, USA

Having just made it over the mountain pass with no previous trouble, we stopped at gas station for more wiper fluid. When starting up our 2000 Ford Excursion a loud boom came from the truck. This startled us and others outside of vehicle including a sheriff that heard it and came next to us to see what is was. We immediately turned off vehicle - sheriff and passer bys thought maybe exhaust?? we made it home but truck now sounds like a loud putt putt truck. We smelled fuel all the way home. As it turns out #10 sparkplug blew out hitting firewall. From two repair shops it is in a very difficult spot and is not likely will hold. So, we took it to Ford dealership to see what they can do. We have been told by Ford dealership that a "bandage fix" will probably not hold and other plugs could also blow or may not - apparently this is not new news to Ford or the other repair shops we spoke with. So to replace just one side of head we are looking at $3680 or $5900 + for new engine. Vehicle is not worth that in trade in per Ford dealership - even before blowout. Needles to say, we could have been on freeway and been forced off road (it was snowing badly and a bang that loud could have spooked many.) so that is why I stated there was a crash as there could have been if we had been driving. Also, not sure if the fumes were cause of illness we had that evening and next day. We smelled fuel and smoke/exhaust all the way home. Also, plug was not found and may have damaged or injured someone or something else. It is very dangerous and irresponsible of Ford to not recall this problem. Only to wait until someone tragically is injured or dies. It will happen. There is no control over where plug blows and what it will take out in its path. It seems this is and has been a problem with various model Ford from 1999 to 2004. Waiting for recall... or Ford to step up and repair this problem at their cost. This is not my design flaw! thank you for your help.

- Gig Harbor, WA, USA

Spark plug blew out of my 2000 Ford Excursion V10 and I am now seeing that this is a growing problem with these engines. I have 5 trucks with these engine and now I am very worried.

- York, PA, USA

I have owned by 2000 Ford Excursion with the Triton 5.4 for 3 years. I have barely put 20,000 miles on it. It know has 110,000 mi. When the spark plug blew on it. I was driving down the road when I heard a loud popping noise and then sputtering. I had to have it towed to my mechanic and had a costly repair done. As I have done research on it this is a ongoing problem with Ford because of the design flaw in the head. I am very disappointed to find out Ford has not recalled this. There is thousands of complaints with the same problem. Ford are you listening" when are you going to do something about this" if this is not recalled soon I will be trading this in and buying a Chevy or a Honda. No more Ford for me.

- Ravenna, OH, USA

The contact owned a 2000 Ford Excursion. While driving less than 55 mph, the vehicle shut off. The vehicle was left on the shoulder until a tow truck arrived. The vehicle then caught fire and a police report was filed. Five months later, the contact was notified by the manufacturer that there was a recall on his vehicle that could result in a fire. His VIN was included in the recall. The recall number was unknown. The failure and current mileages were over 100,000.

- Whatley, AL, USA

Spark plug blow out on 5.4 Triton engine.

- Waimanalo, HI, USA

2000 Ford Excursion V-10 ejected a spark plug while I was taking my kids to school this morning. This appears to be a known manufacturing flaw that Ford refuses to stand up to. Cost to repair was quoted at $3,750. I believe that Ford Motor Company should be held accountable for their inaction to correct a well documented defect.

- Fort Morgan, CO, USA

My wife was driving the vehicle and she heard a "big pop". vehicle became immediately disabled. She called tow company and sent to neighborhood Ford dealer. They stated that a spark plug had popped out of the aluminum engine. I immediately thought "defect" as spark plugs should not be flying out of engine blocks. I took my complaint to the dealer customer service manager & owner. She (amanda) stated that there is a serious problem with Ford engines and that this is problem that they know about. She said they know the threads were "too short" and that it could happen again at any time to other spark plugs. I fear for the safety of my family but with six kids we need the vehicle run our daily lives. I have been advised after the re-tapping "repair" at the dealership that the only Ford authorized repair is a full replacement of the cylinder heads that would cost $ 6,000. This is a whole other issue. Please do not let them get away with this. I am informed that there are thousands of others that are having the same problem.

- Yorba Linda, CA, USA

Our 2000 Ford Excursion keeps having the spark plugs shoot out of their holes damaging the head and individual spark plug coils (3 replaced so far). We have spent nearly $500 repairing the heads/coils so far. I expect additional plugs to fail on the V-10 engine. I am afraid of continued head and coil damage and even fuel line damage leading to an engine fire and total vehicle loss. I want Ford to recall the vehicle and replace the heads with new heads with a better spark plug hole design.

- Corona, CA, USA

Vehicle caught on fire while parked and turned off. The alarm was also on. The fire originated from the engine compartment on the driver's side, per the fire inspector.

- Brandon, FL, USA

Oil leakages due to engine galley plug coming out of it housing on two other occasio. Dealer notified, and unwilling to assist in this matter. Feel free to provide any further details on this matter.

- Stanwood, WA, USA

While driving and when making a right or a left hand turn consumer has noticed a very loud knocking noise when turning. Consumer has contacted dealer. Sway bar repaired. Mounts, bushings, bolts and springs were missing. Steering was lost twice. The dealer had tried to repair but the problem still continued.

- Reisterstown, MD, USA