Join Date: Feb 2001
Location: Ontario, NY (near Rochester)
spark plug blew out on 5.4 triton
That is usually only a V10 thing so hearing it happening on a 5.4 is weird. There are no plug wires, only coil packs that sit on top of the plugs which are recessed in the top of the heads. The coil packs are right next to the injectors and just disconnect the electrick connector and remove the single hold down bolt and lift the single coil pack out of the way. Then use an extension with a 5/8" plug socket and stick it way down in the hole and remove the plug or use pliers or magnet to remove the popped plug. I just went thru this myself on my V10 on #4 cylinder up under the cowl in a super tight area. There is a spark plug helicoil kit specifically designed for the Triton series heads and you don't have to remove the head to repair it unless it's a V10 with #4, #5, #9, and #10 cylinder plug popped. Then the cab has to be lifted off the frame for access(easier than pulling whole engine). Change all the plugs and don't under torque(the reason for plugs popping out from wearing out the treads from the plug moving up and down against the threads on the aluminum heads) or over tighten(stripping out). Have fun and if I can remember the place that sells the Triton specific heli coil kit for the spark plug holes I will post it. The alum heads actually use a tapered seat plug instead of a gasket type which is very strange. Ford has revised the spark plug giving them more threads and now the plug replacement part number is for the newer style plugs. They realized thier F_CK-up without actually admitting it. It's typically $3000-$3500 at the dealer to have the head repaired(replaced actually) on a F250/F350 truck or Excursion/Navigator. I know what the owner is going thru and it is fairly common on the V10s through 2002 when the problem was corrected. The old plugs only have about 3 threads and to top that off many plugs were under torqued at the factory which is causing these problems. $130 for a coil pack(can get for about $90 from Ford with a discount) and the Ford platinum plugs are about $5 each which adds up in a V10. Be sure to blow out the crap from the plug holes on the other cylinders after you remove the coil packs but before you remove the plugs. Spray WD-40 on the new coil pack and on the old coil packs before you reinsert them to help them slide in the spark plug hole and seal better.