Spark plugs blowing out.

- Waterford, MI, USA

The contact owns a 2005 Ford F-150. The contact stated that while driving at various speeds, the vehicle would shake and the check engine warning indicator illuminated. The failure recurred numerous times. The vehicle was taken to a dealer. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 85,000.

- Godfrey, IL, USA

2005 Ford F-150. Consumer writes in regards to vehicle tune-up issues. The consumer stated no one can tell him the estimated cost of a tune-up because the spark plugs can break off when being removed and can cost several hundred or even thousands if the cylinder head has to be removed to deal with the broken plug(s).

- Greenleaf, WI, USA

Exhaust manifold on the Ford' 5.4L engine apparently were not engineered correctly. I have heard of many that have leaked and had to be replaced. I worry about the possibility of fire. I have contacted Ford Motor Co. Multiple times however they declined any help with there replacement on my truck. It seems to be a very common problem from what I've heard and see online. Should Ford have a recall on these manifolds?

- Butte, MT, USA

We have had our 2005 F-150 king ranch for about 10 years now. Today (Feb 10,2015), my wife and our one year babe were heading to the post office the truck displayed a message reading "engine failsafe mode". the truck lost all power, no steering, and it stall on the highway going about 65 mph. Luckily, she said there were vehicles behind her and she pulled it over with no steering and the engine dead. My wife then sat on the highway for about 10 minutes and tried to start the vehicle, which started and there were no "engine failsafe mode" on display anymore. Know with-in the last year our truck has had the check engine light and the ABS light has come on and off every other month. I have checked the fuses and had replace a few but at time it is not the fuse. I've had the interior dim in and out and at times it does not work at all. By reading the F150.net forum found out the a wire that splits into two wires was corroded on the passenger side floor board, it seems that condensation or water come in and stays in that pocket were that wiring harness goes thru. I am now terrified that truck will shut off on the highway again with my family and I in it. This seems to be a life threatening problem. I have read thru some forums and it seems that people have called the Ford dealership and the service department claimed they have never heard of this problem, but can work on it if they bring it in. But that Ford claim that they fix the problem and the people says that the problem still exist. Hope some one can help or assist us in fixing this issue not just for our family but for others too. Sincerely [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Sanford, NC, USA

Bought a 2005 F150 Triton V8 5.4L new in 2005. I have now experienced a cam phase problem which will cost appx 2500 to repair. Talking to my mechanic he said that it was no promise to fix the issue, because these motors are known for this issue. Was told it would be easier to put another motor in so I wouldn't have to worry about, if it would fix the problem. My brother has a 2008 Ford with the same motor and had the same problem, but his motor after having the cam phaser's replaced blew up and had to replace the motor. After researching and talking to several ase qualified mechanics they all said that there's an issue with the 5.4 liter Triton motor. Upon calling Ford Motor Company as I well figured would happen they said that they wouldn't help with the cost and that there was nor recall. Consumers should be able to get more than 100,000 miles out of a vehicle they buy. If Ford wants to keep customers happy they should address theproblem and the government should be more vigilant in assuring the consumer is protected from companies whose product dosen't meet standards. I would like to see the government to look at all complaints through a survey on this motor to find a solution for the consumer.

- Pickrell, NE, USA

The contact owns a 2005 Ford F-150. The contact stated that after starting the vehicle, the engine misfire and the check engine warning light illuminated. The problem recurred multiple times. The vehicle was taken to an independent mechanic. The technician diagnosed that the spark plug was fractured and that needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The failure mileage was 90,000.

- Riverside, CA, USA

Spark plug blew out of head.

- Friendsville, TN, USA

2005 F150 goes into "fail safe mode" and shuts down while driving. It only occurred once per year starting at 65,000 miles, but now happens every 3-4 weeks at 114,000 miles. Once the engine shuts down, I put the transmission into neutral while coasting and it restarts easily. The engine light illuminates for 3-4 days and then turns off. In researching the issue, it seems to be a rather common problem with this vehicle and is usually caused by a faulty throttle body. Ford states that they are aware of the problem.

- Keller, TX, USA

I own the above mention vehicle, there was no disclosure to me at the time of purchase of a very serious design flaw with the spark plugs that could and likely will break off in the engine during replacement and the extreme cost in changing these plugs around 900 to 1000 dollars if no plugs break off and even more in the plugs do break off or heads have to removed to extract the plugs even worse pieces of prshell could fall into the engine cylinder and cause engine damage to around 8000 dollars now that I aware of the extreme cost 3 or 4 times the amount for routine maintenance of changing spark plugs in these Ford vehicles Ford is no help at all saying its not a safety issue I cant help it the design flaw with these long 2 piece plugs is so serious and the price gouging of the consumer for the cost to change spark plugs is so expensive and so bad I strongly feel that the federal gov should step into the matter and help the consumers out and not allow Ford to get by with this extreme bad design flaw and the outrageous cost they are charging and the fed gov should force Ford to recall all affected vehicles and mandate that Ford eat the cost of changing these spark plugs and put in the newly developed plugs that are not prone to become seized to the engine and Ford shall do so at no cost to the consumer safety or not it is just unbelievable they can get by with such a serious design flaw with such a high expense to the consumer for something that is supposed to be routine.

- Eden, NC, USA

The contact owns a 2005 Ford F-150. While driving approximately 60 mph, the engine stalled and the engine failure system warning light illuminated. The vehicle was restarted after multiple attempts. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 103,000.

- Aurora, NY, USA

Over the past 5 years I have had my truck go into fail safe mode. My truck will flash fail safe and I will lose all power to the vehicle. I'm able to coast to a stop. I have been able to re start my vehicle and continue driving.

- San Diego, CA, USA

Front end collision into the rear of another truck. Whole front end damaged through radiator, hood, headlights, bumpers etc. Airbag never deployed and upon return of vehicle after repairs, I am now getting a code 42 that the sensor is bad and after research find out there is a recall on this but for the opposite reason but also now understand there are corrosion issues with the connection of the sensor also. Hope this helps. Please advise what to do, will Ford fix this whole problem and replace with a new sensor and the wire chaffing problem? thank you in advance!

- Las Vegas , NV, USA

I have owned my Ford truck for almost 8 years and I have experienced nothing but bad luck with this engine and me and other Ford owners agree that this engine is 1 of the worst engines that Ford has produced and they know it. And are reluctant to do anything about it. And its costing me thousands to replace spark plugs and camphasers. My truck now will stall when put in reverse. It also has a loud ticking noise to it. I know its the camphasers again which I already replace about 4 years ago.this truck is costing me more than its worth. I only have 85000 miles on it. Ford needs to do something about this problem. Me and other Ford owners of this model cant keep slamming money into something that is a complete failure from the start. This truck is dangerous and the problem needs solved.

- Lebanon, OH, USA

Truck shakes vigorously at speeds over 55mph, cannot excel in fast oncoming traffic with children in vehicle! engine cuts out and jerks the whole vehicle. Misfiring. Continuously having to get towing because the vehicle fails to start all together! this could lead to injury, death, accidents not only for the driver/passengers but others on the roads as well. This issue has been brought to attention in the Ford F-150 5.4L engine more than several hundred times and no action has been taken. You can find information all over of people having the same issues, the Ford dealership I took it to told me I would need a new engine or to spend thousands to fix it and they see people back in there within the month of spending grands to fix it. Something needs done about this before people end up dying in these vehicles.

- Grand Rapids, MI, USA

The 5.4 liter engines have a design problem that's costing owners a lot of money just to replace the spark plugs. The plugs are twisting off or breaking because the block design allows the plug to extend into a hole that allows carbon buildup around the tip of the plug. When you try to remove the spark plug the bottom of the plug is sealed tight to the head therefore allowing the top of the plug to twist and not the bottom. This is happening to a lot of truck owners and some dealers won't even attempt to replace the plugs. If one breaks, it could cost up to $2000 for the repairs. I have 4 of them broke off. I have ordered the extractor kit but the back two cylinders are going to be hard to repair. I like my Ford truck but since the earlier model Ford were blowing plugs out of the blocks and now we can't get them out without an extractor, to me this is not good engineering. I would like to know what Ford is doing about this extreme cost to its customers. Thank you, [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Utica, OH, USA

We bought this vehicle new in 2005. Change oil as required and did regular services. Engine started knocking and running rough. Took to dealer who stated cam phasers went out which in turn blew the engine. Dealer states new engine is required on a 9-year old vehicle with less then 140,000. Dealer states cam phasers are very common problem in this engine (5.4L trinitron). Calls to numerous other local Ford dealers reveal numerous engine repairs due to cam phasers in the engine internet research find numerous issues with the cam phasers in this engine causing complete engine failure. Ford refuses to acknowledge the problem. Dealer quote to replace the engine on a 9-year old vehicle was $7150.

- Springfield, MO, USA

The vehicle began to smell like raw fuel, particularly at stop signs or intersections. The smell appeared to be coming from the engine bay. Upon disassembly of the intake components of the engine to expose the fuel injection system, it was evident that the fuel rail had begun leaking raw fuel inside the engine bay. The fuel rail developed a speck of corrosion about 2-3mm in diameter on the top surface of the rail. The corrosion evidently penetrated the entire rail and became a pinhole leak. Raw fuel was seen leaking up and out of the pinhole. This happened on the passenger side fuel rail, which is positioned inches away from the high voltage coil pack, and above the exhaust manifold as well. Called Ford customer service hotline and was told there is no recall for it, no extended warranty program, no assistance whatsoever. Ordered a new fuel rail through local Ford dealer for $500 dollars (4 times what a typical fuel rail costs); part has not been shipped, dealer unsure if Ford has any in stock or is even making the part. Truck has been inoperable for over a week with no way to fix it.

- South Portland, ME, USA

The number 3 spark plug blew loose. The first time it happened it was just started and idling. It got fixed with a repair kit and then it happened again the next week. It wouldn't be a huge concern but there are multiple things that could happen and cause serious injury and or a fatality.

- Marion, IL, USA

Truck went into "limp" mode on start up. Very difficult to get home in traffic. "fix" was new throttle body from flecther Ford. $582.38. Seems to be an ongoing problem with Ford.

- Joplin, MO, USA