Comment: “I just had a spark plug blow out on my 1999 5.4L which has about 112K on it. From reading more about this subject on various forums about spark plug blow outs, this is obviously a well known, and unfortunately, common event for the 1997-2003 Triton engines. Because the culprit is a poor cylinder head design I am not sure what is the best course for repair.”
Research conducted by GotEngines.com, specifically designed to avoid selling the non-upgraded Ford engines suggests:
The 100K tuneup interval is the root cause of the spark-plug-blowout (among other things). If they were removed and re-torqued and coated with anti-seize and sealed with dielectric grease at 20K intervals the plug blowout problems would probably be mostly gone. Keeping your cooling system fresh is of utmost importance. Of course the problem could be eliminated by installing inserts when the head is built at the factory.
Some of the plug blowouts were caused by leaky heater hose connections and condensation buildup thus damaging the threads, mostly due to the fact the head and spark plug are dissimilar metals. As in aluminum and steel…
None of these situations has anything to do with the head design itself. The actual manufacturing method is the problem. The factory cure, if you want to call it a cure is to add an extra thread to the spark plug for more threaded surface area. I call that a patch repair / update designed to get the darn engines out of warranty.
Using the Time-sert metal inserts is a sure cure for the problem. A Time-sert is installed as per directions in the existing spark plug hole in the aluminum head. This gives the spark plug metal threads instead of aluminum threads to hold it in place. Also available is a similar set-up called a Helicoil. Both are great choices.
May I suggest new head bolts. It’s also a good idea to replace the chain guide and tensioner arm while you are there. Make sure you get all the coolant out of the head bolt holes too. don’t forget to install the crank sensor tone wheel before you install the timing cover or you will be chasing down a no start. The torque spec for the head bolts is 30 ft-lbs in sequence then turn each bolt 90 degrees in sequence twice.
After installing the Time-sert or Helicoil/s, preferably in all the spark plug holes at the same time you have that the heads are off, reinstall the spark plugs with some anti-seize compound and re-torque the spark plugs to 13 ft-lbs. on the nose.
I would recommend 1 drop of Blue Loc-Tite (medium strength) on all bolts except the head bolts and spark plugs ( remember: use anti-seize on them) to keep them tight after you torque the bolts.
FYI- Harley Davidson builds all of their engines now with aluminum heads. They have built the bulk of them with aluminum heads for over 50 years. Harley Davidson figured it out about 20 some years ago, use the Helicoil inserts at the factory when the head is made. Preventive action. Good Idea.
Making sure you don’t buy a used or rebuilt Ford engine with the flaws uncorrected is one reason why GotEngines.com presents this blog. We also have a growing repair guide for the DIYer to make repairs they are comfortable with in the hope of keeping your car longer, due to the economy and making small repairs yourself.
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