2002 Ford F150 5.4 liter engine 2 months ago I had a spark plug thread failure on my F150. It cost $400 to repr the vehicle so that it could be driven. 1500 miles later I have another thread failure causing another plug to be spit out of MY6 cylinder head. I have been told by dealerships and mechanics that this is a common problem and that I can replace the heads with new ones but that they can not guarantee that it would not happen again. Or I can have both heads removed and have inserts machined into the heads to prevent anything from failing again. The cost of this process is $2200. I have now spent $2600 on the engine in 2 months time due to a improper manufacturing of the heads that were made for this engine. I would like to see a defect recall made on the heads and possibly be reimbursed for some of the expense.

- Wichita, KS, USA

Vehicle popped out a spark plug from the #7 cylinder upon starting vehicle. Spark plug was found on the intake manifold, coil still providing spark. Unbrunt fuel mixture was being vented from the cylinder into the engine compartment. I am concerned about fire hazard.

- Mystic, CT, USA

Vehicle started making loud noise under the hood, turned out to be a stripped spark plug hole in the cylinder head that led to complete replacement of head. Dealership stated this was the 4th one this year, always 2002 model, 5.4 liter engine, always right side cylinder head. If a dealership in a town of less than 600 people has a failure rate this high, how big is this problem nation wide?

- Ramsey, MN, USA

I have a 2002 Ford F-150 with 65,000 miles on it. It is the 4.2 liter V-6 that has always been taken care of. The motor threw a rod and needed to be replaced and stopped with a loud banging and the cost was 5,000 for a new long block by local Ford dealership. I have looked on the internet and seen hundreds of folks having to have their same V-6 engine go out prematurely. From 40,000 to 100,000 miles. The plastic intake gaskets are faulty and it gets coolant on the spark plug in cylinder and motor goes out by throwing a rod. Ford does not accept any responsibility for this lemon engine that seems to have many design flaws starting from 1997 when they started putting it in their vehicles. Updated 09/19/07

- Olympia, WA, USA

2002 Ford F-150 5.4L V-8 engine has a blown spark plug, Ford refuses to accept responsibility for the head failure. They make a kit from a 1987 or so escort that had the same problem and they fixed those vehicles.

- Lyles, TN, USA

In the middle of July of 07, my wife, granddaughter and I were coming home from vacation in Idaho, by york, ne. The truck was all of a sudden running rough. I was unable to find a mechanic to let me know what was wrong. I had to drive the vehicle home. I called my son in Idaho, who is a mechanic and he listened to the vehicle over the phone. He told me that it sounded like a spark plug had blown out. I looked and saw the plug on top of the engine. I called around and found out it was going to cost over $2000 for the job. Then I found out that Ford had made a kit for it. In over 40 years of driving I have never heard of such a thing. If Ford made a kit for it, then it seems to me that they should either fix the problem or inform customers about it.

- Leavenworth, KS, USA

The contact owns a 2002 Ford F150. The contact stated that the spark plug injection on the number three cylinder is defective. The vehicle began spilling raw fuel into the engine compartment. He has taken his vehicle to the dealer and they stated that this is something that just happens and the vehicle is not covered under warranty. Currently, the vehicle is at the dealer, where it has been for eleven days. The current and failure mileages were 104,000. The consumer provided for repairs and a letter from Ford Motor Company referencing the defect. Updated 08/07/07

- Galt , CA, USA

The contact owns a 2002 Ford F-150 harley davidson edition. The contact stated that the spark plugs have been backing out. As a result, the failure has blown the coil and damaged the head, which needs to be replaced. The dealer has witnessed this failure before, but cannot offer an explanation. According to a site that the contact visited, this has been a failure with the supercharged vehicles. He has notified Ford, but they have not yet responded. The engine size was unknown. The current mileage is 50,000 and failure mileage was 49,885. Updated 06/08/07.

- Smiths, AL, USA

76000 miles Ford F150 4.2L V6 with a P0174 code replaced intake manifold gasket, maf sensor. $750 dollars later truck runs fine but was told by the mechanic this will happen again ! first and last Ford I will have.

- Greenwood, IN, USA

Vehicle was always maintained correctly, while driving at approximately 25-30 miles per hour, there was a sudden popping noise, vehicle lost power which startled the driver and caused the vehicle to crash off the road. Vehicle was returned to the road and brought to a parking lot. Next day the vehicle was towed to mechanic and it was discovered that the spark plug was blown from the aluminum head. Mechanic tapped the head and owner was forced to spend $600 dollars, or replace entire head for $3500. Minor vehicle damage due to accident, if this occurred at higher speed unknown what could have happened. Pregnant woman in the vehicle who was extremely scared due to noises and exhaust blowing into cabin of 02 F150 V8.

- Sandown, NH, USA

I have a F150 2002 Ford pickup with 55,000 miles on it. My parents and I had just finished lunch and got in my truck. I turned the key and we heard 2 loud popping noises and the motor started running rough (pulsing). Turned the vehicle off, opened the hood only to discover the spark plug had blown out of the #8 hole and was laying down in a crevice on the engine and then rolled out of sight. We had to call a flatbed tow truck and were towed 82 miles back to North country Ford, coon rapids, mn on a Saturday night where we left the vehicle. On Monday morning I found out to my surprise from the service department at North country Ford that the extended warranty I have on the truck would not cover the $2,300 cost. North country sent out the head to have the holes drilled larger for the spark plugs. I have driven Ford products for over 45 years but this will be the last Ford unless Ford owns up to this problem and does a recall and credits people like myself who have been inconvenienced.

- Blaine, MN, USA

Ford F-150 blew out a spark plug from the head, this is a known problem and has happened to thousands of people and Ford refuses to do anything about it. Average cost of repair to the customer is 3500.

- Nrh, TX, USA

My 2002 Ford F150 svt lightning ejected the very back passenger side spark plug. I was idling at a red light, a loud pop, and somehow drove the truck to the nearest Ford dealer. (joe sartain Ford, Decatur, al)

- Stockton, AL, USA

I purchased a used 2002 Ford F150 4X4 from the manager of a Ford dealership. Within 7 months a spark plug blew, we did not know it was such a problem but we repaired it and a couple of months later it did it again we repaired it thinking maybe we did not repair the first one correctly. Then a month later it did it again. I searched web sites and saw it was a greater problem. I took my truck into a Ford dealership-(which say they can not really say what the problem is exactly?) it could be from a blown spark plug.. but refuse to give that as a reason" I wonder why" so they have quoted me about $3200 in repairs not including labor, which will take it up to about $5000!!! I can not afford this as it took everything for me to pay for this truck, which I feel was sold to me by the dealership and even the previous owner of the truck that knew of a problem and did not disclose it to me. So my truck will sit until I decide what to do, as I make monthly car and insurance payments on it.

- Fresno, CA, USA

On two occasions within the last year, my Ford F-150 with a Triton 4.6 liter V8 engine has "blown a spark plug" causing a substantial loss financially and transportation wise. I came to find out that this is a prevalent issue with Ford F-150 Triton engines and I ask that a formal investigation, recall and, if possible, compensation be awarded to me and others having suffered the same fate. The most recent case occurred on Saturday night April 1, 2006 when returning from a family wedding.

- Palmdale, CA, USA

Ford 5.4 V-8 Triton engine spit spark plug my 2002 Ford F-150 supercrew spit out the #3 spark plug. The repair was $500 to have the head re-threaded with no guarantee. Dealer advised next time the head would need to be replaced at a cost of over $3000.

- Franklin, MA, USA

: the contact stated without warning while driving 60mph the number three spark plug came out of the head. The vehicle was towed home. After talking to the dealership, it was determined the head was not able to hold the spark plug in place. The head, coil for the spark plug and the gaskets need to be replaced. No repairs have been made.

- Manchester, MD, USA

Driving on the freeway, loop 375 el paso Texas, we heard a loud bang. We thought we had a tire blowout. Pulled over to the side of the road to discover for the second time a spark plug blew out of the head.

- Apo, AE, USA

: the contact stated while driving 40 mph, the engine made a popping noise without warning. The vehicle was pulled over and upon inspection, the contact found a spark plug on the engine. The vehicle was driven to the dealership. The dealership determined the spark plug blew out of the engine head. A new engine head was installed. Updated 03/09/06.

- Jackson, WI, USA

On 12-29-2005 heard tapping noise coming from engine of 2002 Ford F-150 harley davidson. After accelerating from intersection near home, I heard a large bang and truck lost power. Immediately pulled truck over and had it aaa towed to local Ford dealership. Ford diagnosed the truck and according to the Ford service advisor, #6 spark plug blew, causing damage to left cylinder head. Approximate damage repair $3800. Truck only had 57,000 miles.

- Norwalk, CA, USA