Spark plugs blow off the aluminum heads.

- Avondale, AZ, USA

For a few months after tuning up my Ford F-150 with the 4.8 V-8, my truck started blowing spark plugs out of the motor while driving down the road. I brought this to the attention of Ford and was told it was a common problem with this motor but they would not be responsible. I did my own research and found instances of people running off the road after their plug shot through their hood and scared them.

- Eads, TN, USA

Spark plug blowingout of cylinder head on a 2001 Ford engine 5.4 V. 8.

- Dearborn, MI, USA

Blown out spark plug on passenger side of 2001 F 150 with 102K miles.

- Coarsegold, CA, USA

Spark plug blowout...cost of repair $4000

- Lincoln, CA, USA

2001 Ford Expedition eddie bauer, at about 30 mph, 3rd spark plug blew out stripping threads and ruining coil. We replaced the coil, but dealer will not rethread, the dealer says that if they were to rethread it would not hold and would probably blow again possibly doing more damage to motor. They said they will only replace the head which is $2000. When it blew I was on my way to the airport to pick up family with my newborn and four year old. I was stranded on the highway for an hour and a half in 98 degree heat. My family was stranded at the airport for two hours, not to mention the tow bill. I called Ford, they acknowledge a problem, but take no responsibility. They said it was because of poor maintenance. But my vehicle has been 100 percent properly maintained.

- Dahlonega, GA, USA

Number 3 spark plug blew out, stripping the threads in the head and breaking the ignition coil. Fuel could have been ignited from the dangling spark plug wire after the spark plug blew out.

- Chula Vista , CA, USA

Ford spark plug blowout.

- Cleveland, OH, USA

My F-150 Ford pickup truck engine made a loud pop and a series of pop noises after that in taneytown, md on 4/28/06. Pulled over to side of road and shut engine off. Opened hood and did not see anything, but smelled gas. Started engine and saw a coil and wire flapping up and down. Purchased new coil on 4/29, and attempted to replace. Found spark plug from cylinder on the laying on the top of engine block. I attempted to drive home, but 3 miles down the road, experienced same condition. Brought vehicle to crouse Ford in taneytown, md. Internet searches show that there are a lot of vehicles with the same problem. I contacted private auto repair center to correct. This has cost me over $6,900 thus far. I honestly believe that there is a design defect and a safety issue that Ford Motor Company should be responsible for. There are countless cases of this condition in the Triton engines (from my research) from 1999-2002. I believe Ford Motor Company should be responsible to me, its customers, and the other potential failures from their poor engine design. The head is manufactured from aluminum, and the spark plugs only have 4 threads which is not enough to hold under combustion pressure. Denial of this condition, in my option is consumer fraud. I am seeking reimbursement of total cost of engine replacement and all associated repair costs encountered from this negligence. I thank you in advance for any assistance you can provide.

- Mount Airy, MD, USA

Spark plug ejected out of my engine while driving at 15 miles per hour in Maryland. I mean it actually "blew out" of the head. Stripped the head and cracked the coil as well as the spark plug. I believe there is a design flaw on the aluminum head and the reduced number of threads on the spark plug. Ford dealers have advised me that the only fix is to install a new head of the same nature. Why would I want to replace a defective part with another potentially faulty part? this may cause a safety concern if I was driving faster in a larger volume of traffic. Two Ford dealerships have advised me today that is not a design flaw I believe this maybe a larger problem based on my research and the manufacture should be investigated. This is close to consumer fraud in my mind.

- Mount Airy, MD, USA

I noticed a ticking sound coming from my engine, shortly afterwards it began to pop loudly after leaving an intersection and traveling about 10-15 mph. I had the truck towed to a Ford dealer and was later informed that a spark plug had blown out and caused considerable damage ($4200-$5400!).

- Foothill Ranch, CA, USA

My 2001 Ford F150 recently ejected a spark plug. I have had an ongoing problem with this truck, having it in the repair shop numerous times. Approx. 2 weeks ago during normal driving, the engine blew a spark plug completely out. I received an estimate from a Ford tech. Of approx. $2000. I have purchased a kit to repair this myself. The company made the kit specifically for Ford Triton engine repairs, which shows this is a major problem. I estimate the total cost of my repair will be over $1000.

- Seaboard, NC, USA

I have a 2001 Ford F150 with a 4.2L V6 engine and at 97,500 miles it started to leak antifreeze. A mechanic told me that it is a problem that he has seen in many F150 trucks with the 4.2L V6. He said that the lower intake gasket as well as the timing cover gasket have to be replaced to fix this problem.

- Slidell, LA, USA

Took truck to dealer after hearing low end ticking sound and mil light, told it was tensioner and manifold spacer. Picked up truck 8 days later and still had problem, returned and told by head mech. That it was a normal sound. Drove home and it was missing badly. Returned was told had a bad plug, truck is still ticking and loudly. Dealer washed hands of problem.

- Miami, FL, USA

Our Ford F150 has 46,000 miles on it. On Friday the 14th my husband was driving down a residential street when he heard a loud banging under the hood. He pulled over right away and the engine died. He looked under the hood and could see that the distributor cap was broken and flopping around. He had a friend tow the truck to the friends residence so that the truck wouldn't be left on the side of the road. My husband then called a tow company to tow the truck 18 miles to a nearby dealership to examine the truck. We were told that the spark plug threads were stripped and that new heads would be required to repair our truck. We were also informed that our extended warranty did not cover this repair and that our bill would be approx $3,200. After the tow bill, parts, labor and rental car we are now up to $3,500 in expenses.

- Oroville, CA, USA

2001 Ford F150 supercrew 5.4 liter Triton V8 engine. On Sept 16, 2005 my truck experienced a #7 spark plug blowout. The head was replaced. One month later, the other head experienced a spark plug blowout. It seems there are not enough threads to hold the spark plugs in the engine during normal operations. The engine only has 71,000 miles on it. At 60,000 miles, the Ford service center replaced the spark plugs in accordance with the Ford Motor Company manufacturer specifications and recommended maintenance schedule.

- Dixon, CA, USA

The contact owns 2001 Ford F-150. There is a clattering sound coming from the engine. Upon inspection of the vehicle the dealer stated that the engine needed to be replaced. The reason for replacement was that there was a rod knocking in the engine. The manufacturer has not been contacted. Updated 11/16/05.

- Carrollton, TX, USA

I was in the parking lot of a store and when I went to start the truck it made a huge popping sound upon investigation I found that the spark plug shot out of the hole after contacting my Ford dealership they informed me that this has been an ongoing issue with the 5.4 and V-10 motors the problem was the spark plug could only be installed using three threads and that they have corrected that problem and now when I fix the truck the new heads you will be able to go down 5 threads at the price of $1300 per head and the total cost of $3200 parts & labor.

- San Bernardino, CA, USA

The #3 spark plug blew out while accelerating from a stop sign. My small town mechanic said he is seeing 4-5 of these per year and blames a design defect in the Triton 5.4 head. The head is too thin and made from aluminum so the threads strip out. The truck has 70,000 miles and the plugs are original. Ford has changed the head design but won't admit to the flaw. This could have been very dangerous.

- Cold Spring, MN, USA

While the consumer was driving a spark plug blew out on 7-30-05. When the consumer took vehicle to the dealership put the spark plug back in its place. The problem has not occurred again. The service engine light came on and the engine was running rough. Other than the above entioned problems the consumer had no other trouble with the vehicle. The consumer believed the problem was with the engine.

- Tipp City, OH, USA