Spark plug getting blown from the head, damaging the head in a 5.4L Ford F-150. Repair was done by myself, using a big-sert repair kit from time-sert. This was the second time it has happened.

- Scarbro, WV, USA

While driving at approximately 30 mph engine made a ping noise. It sounded as if something broke. Owner called for a tow truck and had the vehicle towed to the dealer. The vehicle was put on the diagnostic machine, and owner was informed that the spark plug ejected from the cylinder head that because it was made of aluminum, and if the spark plugs were tightened too much, or the spark plugs were cross threaded when installed they would be ejected.

- Lodi, CA, USA

2001 Ford F150 caught on fire while parked.

- Missouri City, TX, USA

While parked for 24 hours vehicle caught on fire in the engine compartment where the cruise control cable was located. Owner was able to put the fire out.

- Nokomis, FL, USA

My truck developed a vibration and began to have trouble accelerating. Sometimes it would shake violently at idle. I brought it to my dealer and had a technician ride with me. He felt the shuddering and said my engine was misfiring. The coil pack and plug (I believe #1) had to be replaced. This, of course, occurred just after my truck was out of warranty (47K miles). An employee told me she had the same thing happen to her truck after she bought it used.

- Centreville, VA, USA

I own a Ford F150 5.4L lariat 4X4 that recently had a blown plug in #4 cylinder. My truck has 9200 miles on it. I was driving down the road when this happened. I drove the truck to a Ford dealer on all 8 cylinders for a tune-up and advised of what had happened. They acted oblivious to the problem and supposedly their 20 yr tech could not get the 4th plug back in all the way when he was supposed to be changing the plugs. I later found that "blow bys" in the Ford 5.4L engine is actually very common. The mechanic at the Ford dealer totally stripped the #4 cylinder and Ford wanted to charge me $2700 to replace the head. I took my truck to a private shop and had stainless steel sleeves put in all 8 cylinders, since the problem is due to the heads being aluminum and the plugs being steel. When these 2 dissimilar metals expand and contract at different tempatures, causing the plugs to eventually work their way out. How do we get Ford to own up to their design issue and stop passing on the problem at the consumers' expense?

- Spring, TX, USA

The consumer complained that on two occasions, the spark plugs failed. When the spark plugs blew, the entire head needed to be replaced.

- Cedar, MN, USA

The consumer complained that on two occasions, the spark plugs failed. When the spark plugs blew, the entire head needed to be replaced. The consumers wife was driving when the incidents occurred. The dealer replaced the head within 12kmiles in which it blew another spark plug out of the other head. The consumer was told that it was from an internal backfire that was so strong that it blew plugs out. The consumer was aware of others whom experienced that same problem. (cylinder #7 specifically)

- Cedar, MN, USA

2001 F150 lightning.blewout a plug from the head 24030 miles on engine.

- Sunnyvale, CA, USA

Problems with knocking noise coming from the engine compartment. The vehicle was taken to the dealer before the warranty expired. The consumer indicated that Ford Motor Company is aware of the problem with the 5.4 liter engine but they have not fix them. The consumer would like the vehicle repaired or his money refunded.

- Syracuse, NY, USA

Bought a 2001 Ford F150 lightning with 32, xxx miles on 4/16/04. I was driving the truck back from Michigan to tampa, fl, and after refueling my truck, went to start it up and blew a spark blug straight out of the cylinder head. After doing hours upon hours of research tonight, this seems to be a common problem with no recourse from Ford. There is no recall or tsb on the 99-02 F150 lightning cylinder head, yet in 03 they redesigned the cylinder head with added threads to keep the spark plugs intact. I feel that with so many people affected by this, something needs to be done about it.

- Broad Brook, CT, USA

Spark plug blew out of driver side cylinder head, on an 2001 Ford, F-150 lightning all factory 5.4L supercharged V8. Vehicle was traveling in extreme rain at around 40 mph, and 1000 RPM. Vehicle has 31,000 miles, and no modifications have been added to the vehicle. If the vehicle was running at a higher RPM, spark plug could have become a projectile injuring somebody, or causing a wreck at 5:00 traffic time.

- Grapevine, TX, USA

2001 F 150 5.4 L engine driving along and spark plug # 3 blew out of the head.

- Bowie, MD, USA

2001 Ford F150 "lightning" 5.4L V8. Blew out the 3rd spark plug back on the passenger side head. This is due to a small number of threads that hold the spark plugs in the head on 1999-2003 Ford F150 lightnings, as well as other Ford products that utilize the same head design (mostly 5.4L V-8S). Head was replaced under warranty, along with the coil pack that was destroyed by the ejected plug. Do not know if an open cylinder could have caused a fire.

- Florissant, MO, USA

The rear passenger side spark plug blew out of the head at normal operating speed (40mph). This appears to be a common problem among the Ford F150 Triton V8 engines (having reviewed several internet web sites). There is a design flaw where the rear passenger side cylinder overheats and causes the sparkplug to blow out of the cylinder head. Consumers must be made aware of this situation and Ford needs to take responsibility and be held accountable. If I were on the freeway with my children in the truck when this failure occured I shudder to think of what could have happened. Shame on Ford!!!

- Carlsbad, CA, USA

I own a 2001 harley F150 Ford truck which has a consistant problem, not diagnosed on several occasions by dealers, the service engine light continually pops on. I was told that the truck had to be in the shop while the light was on in order to diagnose. Shouldn't the computer record this information. It's still not fixed and now the truck is out of warranty.

- Tempe, AZ, USA

While traveling on the highway and without prior warning vehicle will shut down.

- Apache Junction, AZ, USA

On this date I was summoned to pick up my 2001 Ford svt F 150 pickup from mc gilvray Ford in athens, tx after replacement of my engine valve lash adjusters had been made in an attempt to stop right side engine ticking. The vehicle still made the noise and I got the mechanic to listen. I asked him if they checked the spark plugs because they are known to loosen on this type engine due to poor engineering. The mechanic dismissed my concern and informed me of that they didn't know what the noise was and that I'm supposed to drive it a while and see if the noise lessens. 1 week later this same vehicle blew a spark plug out thus stranding me on the highway. I believe it to be unjust that Ford Motor Company can sell a defective product to their customer and not fix the problem. This is a widespread problem in the engine and it would be proper for Ford Motor Company to replace the product with one that will not fail again. Supposedly there is an improved version of this engine head, but there's no guarantee that my head will be replaced with this newer type. The other head now will also be sitting there waiting to blow also.

- Jacksonville, TX, USA

Vehicle smokes almost every time when first cranked up. Is now beginning to smoke while driving some, especially within a few minutes of cranking. Vehicle stalls mostly in afternoon when outside temp is above 70. Vehicle has slight shake and vibration when driving or sitting still with transmission in gear. Vehicle makes clunking noise around front to front left side if allowed to coast to around 20 mph then accelerating.

- Clinton, NC, USA

Consumer called complaining about having problem with the head gasket which is leaking oil. Consumer states will replace the engine. Dealer has been notified. Please provide further inforrmation. Thanks.

- Locust Grove, VA, USA