We used my truck to tow our brand new travel trailer to an RV site about 100 miles away from home. All was going well until we decided to take the truck from our camp site to go watch some local races at the drag strip. We were about 1/4 mile from the dragway when we heard a loud bang from the engine and after pulling into a safe location we found that we had blown a spark plug from one of the cylinders. This is where our nightmare began. We were scheduled to leave the RV site the next morning. It was too late in the day to contact a repair facility.

I had to rent a truck to take our camper home. We paid a man $100.00 for him to drive us from where we parked our truck to the truck rental location. I had to pay $137.00 for the truck rental. We paid $456.00 to have our truck towed home. I've been researching this issue and it looks like the cost is going to be anywhere from $700 - $3500 to have this issue repaired. I don't have that kind of money right now so my truck sits broken and we have a camper we can't use. Ford seems to think people will just not complain. Well I'm complaining.

This is actually the third time a spark plug blew out, but it's the second time with this one cylinder. A sleeve was purchased through the dealer and put on but this last time the plug blew out with the sleeve still attached. I took it back and now that the sleeve blew out too there's no larger sleeve to fit the now larger hole..PASMF!!

For as old as this problem is and for as many vehicles has this 5.4 engine in them I don't see why this hasn't been remedied. There's class action suits on certain vehicles and years but not on that same engine they keep putting in vehicles. If somethings going on that I'm not aware of pertaining to how this problem has been fixed can someone let me know.. devincurtis19@yahoo.com

Went out to start my truck for work and kapow it was a loud explosion from under the hood and smoke blue in color. Looked at the engine and one of the coil packs was laying near the top of the motor. The spark plug was laying on top of the motor too near the fuel rail. I have had it and it is going to be very expensive.I paid 29,000 for this truck brand new.Hard earned money working 6 days a week.I have had it with this kind of negligence on behalf of Ford Motor Company. I will never buy another Ford truck that's it for for me F.M.C. John M. Roddy given under my hand this day 09/23/2016

I never had a problem like this before. I have owned two F-150 pickups and they were great. I bought a used F-250 v10 and this truck is about to change my opinion of Ford all together. The spark plugs are blowing out and there is no end in site. I have owned the truck eight months and I'm already two plugs in.

I happened to be across the street from a dealership when the first plug blew so I walked over to get an estimate for the repair. For one plug repair I was quoted about 500 dollars plus tax!! Wow, immediately I replied that the repair of ten plugs was the same as the cost of a new engine!! The guy goes yeah, but all ten won't fail at the same time. But eventually they all will. I don't want this problem but at the same time how can I sell this to someone else. Stuck, I don't know what to do.

The other day I went to the bank, went I came back out to start my truck it was like I shot a gun off under the hood of my F250. Have you I'm a lady so I'm scared to death. I called my local shop and he had me try to start it up, then asked if the engine light was flashing. Once I told him no, he told me to get it in there it wasn't even a mile away ,but if you could have seen the looks on people's faces my truck sounded like a piece of sh*t and I take good care of my truck.

Once I got there they told me it was a spark plug and that Ford has been having this problem. WTF I get on here and see several people have had this happen, but still no recall BS!! The guy told me hopefully it's an easy fix and you don't need a new head! Well I was lucky this time, but I have to worry when is this going to happen again? Why isn't Ford doing something they know this keeps happening!! Feeling really angry!

Ford F250 2001 6.8 V-10 Spark plug blow out

I just had two of my ten plugs blow out on my 2001 F250 Gas 6.8 V-10 with 161K miles.

I tuned up the engine at the recommended 100k miles using the specified procedures for this engine. I knew there was a problem with this engine and was extremely careful during the tune-up and plug replacement.

I am a certified aircraft mechanic with FAA inspection authorization. I used a certified torque wrench to install the plug with the correct torque. There was no error in technique or installation on this spark plug replacement.

I just paid $720 to have two spark plug heli-coil inserts done on this engine that blew out the two front left plugs.

There is a similar procedure for aircraft aluminum cylinders (called jugs) with stripped spark plug boss defects.

An aircraft spark plug has a larger 18mm diameter plug with full depth threads (not the ¼” thread of the Ford V-10 and other Ford engine designs). Aircraft spark plugs are torqued to 35 ft/lbs (vs the 8.9 ft/lbs (107 in/lbs) specified by Ford). The maximum rpm of most aircraft engines is 2700 rpm as opposed to 6000+ rpm in the Ford engines. This results in a significantly less stress on the plug boss area that it would have in a Ford engine.

The engineering thought that went into this Ford design is totally nonsensical or non-existent. There is NO logical reason that they should design this thread depth with ¼” depth in an aluminum head instead of the fully available 7/8” of the spark plug threads that are installed. This is a gross error in design consideration that has resulted in thousands of spark plugs blowing out of Ford aluminum heads.

How long before my remaining 8 plugs blow? Where will I be when it happens? What will be the resultant damage to the engine, vehicle or persons in the truck? How much will it cost to repair?

The only legitimate recourse is for Ford to repair this design error. This can be done in two ways. It can be done by removing the heads and threading full depth plugs into the head or by heli-coil inserts in the heads without removing the heads.

We have a Ford 2001 F250 in which the #5 spark plug blew out. We took it to our local mechanic to have it helicoiled as we'd heard many have done with this typical problem - great idea F.O.R.D... - and the plug was stuck. The mechanic had to soak it overnight to loosen the plug but the damage was already done as part of the plug had broken off when it blew thereby damaging the cylinder. We're now facing a very costly repair. To add insult to injury, the truck is only a couple months out of warranty & Ford will do nothing.

Our F250 Super Duty V8 was purchased with 133,000 miles on it with the spark plugs already helicoiled. We felt fairly safe purchasing it as the common problem of spark plug blowouts was, we thought, corrected. On the way back from a very long trip, the truck started running very rough. When we got home, it was discovered the coil was loose on #5 plug - when my husband went to remove and change the spark plug it was discovered the plug was stuck. We brought it to a very reputable mechanic in our area who had to soak the plug overnight to remove it only to discover it had already been heli-coiled. So, now what?? We have to have it scoped to make sure nothing has broken off into the cylinder and go from there $$$$$ Very angry at Ford for not owning up to this obvious defect!!

4th time this truck has blown a sparkplug. Very expensive. I took it to a Ford dealer in Wasilla, AK while on vacation. He replaced the plug, and I had the remaining 9 plugs re-torqued. Drove over 4,000 miles home to NC. No problem on return trip. Ford does not share its torque specs with independent mechanics. Therein lies the problem (in addition to major aluminum block problems which they won't acknowledge). I'm writing Ford to recoup some of my losses. If they won't help, then I'm done with Ford products.