Why the spark plug blew out of your ford Triton engine (the sequel) 

Hey man from one mechanic to another thanks for a great video. And I'd like to say that some people you just can't help, they think they know something when they don't, and unless they've been there and done it like we have it's hard to convince them. Keep on being the best you can be and help those that you can help.

Ford should’ve had a recall and use cal van inserts to fix the problem. Plus their engineers to redo the cylinder heads design. They should’ve known better that 4 threads wasn’t enough to hold that kind of pressure.

My 2005 4.6 spit out a plug a week ago. You are correct 4.6 will blow plugs.Thank you for your videos vary helpful.

Ive had 2 spark plugs blow out of my 2003 mustang gt. And it has the 4.6. Gotts love people who think they know everything. You're videos have saved me sooo much time and money. I do all my own work and this was a first for me. I love my Calvan 38900 !!!!

Ron Thank you for making your vids!! 2002 F150 4.6, 133k. Blew out # 3. Found out about the bad Cal-Van incerts the hard way. Called them and they made it right, sent me 8 new ones right away. Found #5 finger tight (surprised?) went ahead and "Cal-Vaned" that one too. I am a very accomplished DIY mechanic, and I still use videos like yours to help me keep my stuff on the road. Bore scoped all of the rest of the threads. They seemed sharp and present, so 17 ft pounds on new dry Motorcraft plugs. I should be good to go. Thank you again!

I just did the #4 plug on a 2002 4.6L... oh hell yes they blow out. And yes, the #4 is definitely a pain in the ass! 440K KM, I've owned it for almost a year and a half and judging by the plugs that were in #4 and #8... they had been in there a LONG time. Ron, THANK YOU for the videos! They are pretty much the only reason I got it fixed and back on the road so I could get to work. I couldn't do the Cal-Van kit because of price and availability, but I did find another that addresses some of the concerns mentioned in this video and it only cost $50 CAD! That said, it did have the same inserts with only 4 threads. If I can find the dimensions, I'm going to make my own stainless ones with a head on them (I'm a machinist) that are fully threaded.

Thank you for taking your time to make these videos! I was going to have to machine my own alignment sleeves. Everyone pushes the other kits on the internet! My 2002 6.8 just rolled past 240k and this was the first event. Have a great one brother!

Rob your approach and overall logic about this installations is so consistent that I have become "Blindfolded" and I will follow whatever advice you provide.. I'm one of those "One less thing to worry about" persons, maybe because I work on helicopters and rally bikes for many years were absolute reliability is kind of matter of life and death... Thanks for sharing so much of what you know.. Ricky PS: Hey maybe a silly idea, did you ever consider taking a trip around the country fixing heads ...?? Now that Diesel Ron is gone (rIP, hell of a man) is only you left to do the job at 110%

Just got that kit and was so easy to use. Turned a annoying job into a breeze. Thanks for the video.

Fabulous video. Logical, concise, helpful. My mechanic especially appreciates as it took him off the hook with my friends (doubters) who wanted me to blame him for the problem, that I said was just a coincidence and not his fault.

Thank you this has been the most helpful video I have watched. Mine is a Triton 5.4 and it blew out you guessed it the number 3 plug.

Number 3 on my 5.4 blew out at 210,xxx. I'm putting cal van inserts on all 8 plugs. Had leaking intake gaskets and let me tell you it was a breeze doing the inserts without the intake on. Also changed valve cover gaskets while I was at it.

I am a technician. Thank you for your videos!!! On Saturday morning September 19 2020 I blew a spark plug out of my 6.8 V10 2005 Ford Excursion. Cal Van tools worked great!

Lost #8 on my 6.8 and did a lot of research that led me to your video. I ordered the calvan kit, and had it fixed in under 30min. I'm sure it would of taken less time if I had a larger air compressor. Thanks for the info.

Very good video, I've been a mobile tool dealer for 35 years, the CalVan kit is the best, sold many of them and everybody loves the kit and how great it works.

I have just watched your video and you do explain everything in great detail. Even if some people watching are not mechanically inclined they will understand. Thank you for such a Fantastic video.

I blew a spark plug in Thanksgiving, I ended up driving it home with no power, bought the calvan kit and put the insert in the affected cylinder and solved my problem and still have 7 other inserts for when it happens again

Sharp Man, I believer you whole heartedly. I have the exact same experiences as you. I have been a Mast Mechanic since 2001. Everything you said to the best of my knowledge is true!!

You are so right.. 😊I just had a blown spark plug on my 2001 4.6 Ford f150. So your trolls don't know what they're talking about. 😮

4.6 3V “VVT”was in the Ford Mustang from 2005-2010, also in the Explorer. Could also be ordered in the 2009 and 2010 f150.

I’ve had to insert 3 different 4.6 and 1 5.4 with the calvan kit. I’m here to confirm that they do indeed blow out spark plugs. My personal 02 mustang gt blew its spark plug out at 103k miles. I’m a second owner and 1st owner had all his maintenance done at the dealership. Babied or not, it will happen eventually

Good job Ron. Obviously you've dealt with this a lot. I inherited my father's 98 F150 with the 5.4 with 224k miles on it. Never had an issue with the plugs blowing out and I just recently changed all of the plugs without issue. After going back and watching your videos, I'm sooo glad that I took the time to properly torque the plugs. Thanks a lot for the knowledge

I am not trying to be too argumentative because you are correct about the quality of the inserts, but the tap gets centered by the socket that just about fits the hole perfectly. I used the cheap kit before I saw this video. I had a different issue entirely. The tap had a size 19 mm hex head, but a 19 mm would not fit in the hole. The largest size that I could fit in the hole was 17 mm. I just resized the tap head and used a 17 mm deep well socket.

Ron, God Bless, John from Noblesville Indiana. I watched you over a year ago after I got back into Fords after getting started in Fords with my 69 F350 12' flat-bed dually 300 six 4 speed in 1988. I've returned, love all makes though... Your are a giant value, truth never lies. Yes, truth never lies. My 02 Excursion just blew one at 230K day before Xmas on the way fir last minutes food stuffs. Love the vehicle, I will merely follow your lead, you are a great help, more power to you, "GET R DONE" BROTHER!!!!!!!!!!!

2003 4.6 Crown Vic 140xxx. Replaced the plugs myself with OEM around 80xxx and just had one pop out on my way home from work yesterday. Appreciate the videos!

345k miles and just got my first one today lol :D was at DG and had it idling went in for less than 5 minutes come out and put it in R and "TRACTOR NOISE"!! Limped it home and here I am now lol

blew out plug on 03 5.4 cyl 7 fixed w/ sava thread 2016. Replaced all plugs and coils be safe. so far so good. at 272k now and she's still running. drove out of a ditch in nc dent on tailgate only. I'm a novice at this so these vids really help. thanks

I found this so very helpful. Thanks, and I'm subscribing right now. You're the only one to explain the problem with my 2002 5.4. And it's the # 3 plug just like in your video. I've never liked working on ford's. I'm a GMC kind of guy.

Working for a private fleet with a lot of 4.6's in vans, I saw constant blown out plugs. Now working for the county, I see a lot of plugs blow out of the crown vics with the 4.6 also.

I agree with your observations about the 5.4 ford. I have not had one blow so far. Changed plugs at every 10,000 miles. And my truck has 300,599 on it now. I try to do my maintenance in specified periods. Or when I find the parts on sale motorcraft plugs and k&n oil filters with Castrol synthetic blend oil. Still following your video thanks.

Well i came to this channel today because my 97 ford 4.6 Triton f150 blew out a spark plug .i was curious why it had done this since i change these plugs 2 yrs ago and had not had any problems. So thank for the informative video .

Thank you for sharing this version video with us.

Before anything thank you for teaching us. I remember when my uncle told me about this issue and you explained it just as he did. The problem starts on the top and poop runs down hill, The problem is that as you said, moms get stuck with it and they get splattered. We just have to clean up that mess. But thank you. May God Bless You and your Beautiful Family.

Hi Ron ! Right on with the popcorn spark plugs. I have a 99 F-150 4.6lt V8 Triton . It has 267,484 miles on it . My dad was the other owner when bought new . Spark plugs have always blown, atleast every 3-4 years .

Happy to say i was able to install my first cal-van insert! Everything went smoothly, Ron thank you very much, if it wasn’t for the videos I wouldn’t be able to do this. Keep up the good work and keep them videos coming. 🙏

Didn't have time to watch the full video unfortunately! But I seen a post about this engine and got a bit curious, very informative video! And I gathered what I needed in my short time I had! So easily that I had time to write you a comment, Good luck with the channel you're doing well! 😊

Thanks for the video... I bet this is what just rolled in the shop. I maintain a fleet of transit busses with 6.8's one just came in sounding like a rod hitting the pan...missing and I bet it's got a plug blown out.....I have not had time to check it out too far yet.... Thanks for all the info!!!

Number 3 plug on my van blew out so you video hit the nail on the head

You do a great job Ron, liked/subscribed. I have a 98' 5.4 , getting ready to do a spark plug change , never had a problem - 195K miles - knock on wood. But it always makes me nervous so I brushed up on ''what if'' senario . I'll certainly use the kit you recommend if the nightmare happens.

Very grateful for this video. Thanks Ron. 🎯🎯🎯

My 4.6 2v blew a plug on 2nd cylinder... as soon as it popped i knew it was time but CalVan is definitely a must

I have over 1/4 million miles on my 4.6 with no blown out plugs, but it has a funny vibration in it. I may check the torque on the plugs. Thank you for this video. I am looking at an expedition with a ... blown spark plug, that I can get for cheap. The Cal Van kit may be a good investment. I can get proper torque specs from the ford site on the internet, just in case I need it.

Thank you sir I just use that kit from Amazon it works awesome I inherited a 2002 Mercury Mountaineer with the 4.6 V8 only has 90,000 miles on it and popped number three cylinder and it only took me 45 minutes to install that kit is awesome I can see why you recommend it and I recommend it highly just been the extra money for the kit

I've got a 1998 F150 with a 4.6L at just over 122k miles. Just changed the plugs and so far so good, runs best it ever has since I purchased it 2 years ago.. Made sure to follow all recommended protocol and procedure in getting the job done so I am confident I did everything corrrectly but I am also cautiously optimistic that a failure won't happen on down the road given my propensity for bad luck lol... Expect the worst and hope for the best😆

Look the man said look intro my eyes "I'm here to help you with these problems" Ok i can dig that!

Had to pause this video at 4:11 to comment that I just fixed this problem yesterday after blowing number 8 spark plug completely out of the head! 2007 4.6 E250 service van. Exactly as you stated. I love my Fords but this shook me.

From 6:10 to 6:20, when you shined the flashlight on the threads, you answered a question that's been bugging me since I learned of this plug blowout issue. Now, my only question is, WTF would they not tap drill it straight, instead of reamed tapered? Insane! Anyway, I've owned an '06 Explorer w/ 3V 4.6L. Changed plugs twice during my 10 years of ownership. Faced the broken plug issue on #5. Lisle 65600 tool saved the day, and using impact to remove remaining plugs got it done without more issues. Just purchased 2003 Expedition 5.4L, w/ 119K from S. Carolina, to replace our Ohio ravaged Explorer. My research led to the '03 Expedition to avoid the 3V problems, but I failed to learn about the plug launching problem till after the purchase! Still haven't taken delivery, but I'm already preparing to install inserts when I change plugs & coils. I'm betting this truck still has original parts still installed, but won't know for sure till it gets here. I'd like to drive this thing from here, near Cleveland, to Boston this summer, with peace of mind the trip won't be interrupted by a plug ejecting. Would installing 8 inserts be going overboard? How difficult is access to the rear plugs? No qualms about removing brackets & hoses, but not too keen on pulling fuel rail or intake. Oh, BTW, thanks for al the videos. Subscribed!

I have used the sav a thread tool and inserts on all 8 cylinders on my 2001 F150 (over the past 19 years) and once fixed, all of them held up fine! I just did the last one. If you use this tool, get the long inserts and make sure you cut down to the bottom. Use lots of greese and wipe off metal shavings. Kit costs about $30 with inserts. I used the same tool on all 8 plugs' threads!

Ron, I like your video. You are a straight shooter. I can see why Cal-Van is the only insert that really works for the 2V Triton. I don't even see how a Time Sert would work.

Well just had my first plug to blow out of my 2002 Mustang GT 4.6 with 144974miles. I noticed a small (EXHAUST LEAK SOUND) coming from engine bay a couple of days ago and didn't know what it was and didn't pay attention to it right off, and now I regret it. Thanks for this video, I will be buying the calvan kit and D.I.Y

i just did my 2008 town car after 52K miles it had full threads all 8 cyl! good video!!

Thanks so much for your vids Ron. Ive got a #2 cylinder to do a 6.8. Cal Van will be my choice. I apreciate you. God bless

Once again Ron you are the bomb. I just purchased the Cal Van kit and will start my repair tomorrow. Blew a plug on a 4.6 2 V on a 2009 Ford F-150. The most difficult part for me is determining if the valve is closed. I will figure it out I think. Thanks again for giving of your time and your effort for nothing more than to help people like myself. I will give an update on how this repair went. Oh and for the record I have a 1997 F-150 with the 4.6 with almost 300K miles and have yet to blow a spare plug but I purchased the kit for WHEN it happens LOL.

Have seen 4.6 pi and 5.4 blow sparkplug out and thanks for the lesson and suggestions for cal -van

2010 4.6l e250 300k miles, started blowing plugs. Thanks for info, will attempt fix when my kit arrives!

Hi Ron Just watched your video and you are 100% accurate. My 29 year old son just limped over to my house his 2004 F 150 pick up with a 4.6 litre V8 and it was making a loud racket and not running right. Upon further inspection We discovered that his coil pack on cylinder #6 was broken away with his spark plug blown out. As a jack of all trades mechanic/ fixer of most things I had NEVER seen anything like this before.once we cleared the area and removed it from lying loose we called a place called Canada Engines and they said they could fix the issue for aprox $700 and could do this with my son only losing his truck that he needs for his job for only 1 day. A huge relief as it could have been much worse. But shame on Ford for designing a cylinder head with only 4 rows of threads. Thanks for posting this as it is vey informative. Cheers Rod

I use the first repair kit you showed,and use JB weld instead of a thread locker in my 4.6 2valve 8 years later it start leaking so I removed it and replace it with the same kit from Autozone for $47 and use the same JB weld not thread locker and Maybe it will last for another 8 years by then I will probably sell it for a newer model it is a 2004 Ford Expedition with 125,000 on it.Still runs and drive at its best, I replaced the IAC valve and now it idles perfect like new.

You lost me the first part of the video on type of engines, but I do have a 2003 f150 4.6L and right around 129k miles my #4 cylinder plug blew out. Thanks to small time mechanic he installed a new insert and got my truck running again. After doing my research come to find out Ford cylinder heads like you said, has only a few treads holding plug like anything else metal will expand causing plug to work it self out. Great video thanks

I have a 2003 f150 4.6 and I blew one out today. Thanks for the video.

I hope you see this comment cause I just wanted to say thank you and your a honest good man . From a subscribedr !

Thanks for explaining all this to us very clearly.

I have a 4.6 and I can verify that YES they do blow spark plugs! Thanks for the video.

My 08 Ford F 150 has a 4.2 liter and as of this minute it has blown 3 times. 3rd time now last night on a country highway and I found that plug - a miracle, and 1 other time.

Thank You Ron Williams. You video is very important information that all F150 pickups owners need to see it. I bought my f150 Triton with 190,000 miles, just went over 200,000 and I haven't had no problem yet. but I'm now wondering if it will happen to mine. I'm even afraid of checking the number three plug. Once again Thanks You Awsome. N Shame 😢 on Ford for not having a recall on Our F150 pickups.

I have 5.4 litter triton engine I'm going to be working on In the morning ... Hoping it's just the top side of the plug that's rounded off ... If it's the treads that are.strip out then a guess I will be ordering the Calvin kit ... I did do some research on the kit and I'm 💯 percent sure I will be using it to fix this problem on this engine....

Great videos, my 02 F150. 4.6 has done 3 of them now. Last one was today after pulling out of a parking spot. Really frustrating.

The cal van kit just makes more sense and was engineered better

My 2008 Ford F-150XLT 4.6 L Blew No. 3 spark plug at 211,000 miles. Blew it completely out of the hole. I had the smell of gasoline for months before it blew. Unfortunately I was unaware of the problem aluminum heads in Ford and other manufacturers were having with blown spark plugs.

Thank you so much for your videos. I'm a weekend wrencher(clutches, brakes, ect) and you helped me fix my '05 F150 (5.4L, 160K miles), and our '03 Town car(4.6L, 72K miles). I was a bit nervous as i don't do much machine work. My electric ratchet didn't have the power to bore or tap, but a husky air ratchet worked perfectpy. The Calvan kits i bought worked perfectly, minus having to adapt to the air fitting for the tool that detects the valves being closed. I just did 8 of them on the town car yesterday. We love the town car, it has been family owned since new. I used a $15 scope camera that plugs into my phone usb.

Thank you for the detailed information. Pending repair.

good luck with these ford motors...thank you for this info,,, really eye opener...

The hell with the trolls I just blew a spark plug for the 3rd time and I have a 4.6L v8 triton Ford F-150 2001 my truck has over 300.000 miles and this time my threads are stripped out that’s why I’m here I appreciate your knowledge about my problem Thank You

The 5.4 Triton comes in 2 variants. The 2 valve that can't keep spark plugs in. And the 3 valve that you can't get the plug out without it breaking. Cal van or big serts are the fix for the 2 valve and the broken ceramic plug kit is the cure for the 3 valve. Though I've had very good luck on the three valve engine by removing them with the engine still hot with an impact gun (not kidding, it really works the best).

Great video, ty so much. i learned so much from your knowledge. you sir are a great mechanic. I am a garage, bike mechanic, learned how to do alot of wrenching myself, due to being cheap, and fixing it myself, when it breaks down . Cause you know what they say" H.D=Hundred Dollars! lol I have to repair my M12 x 1.25 HD sparkplug hole, i had a TIME-SERT in there, and it walked out..why..lmao..CAUSE I TRYED TO REMOVE THE PLUG HOT/WARM!!. im going back in the whole with GREEN LOCTITE, and another SERT same size...wish me luck, ty again! work safe!

Mine just blew out plug at 130k miles. Got mechanic to do helicoil to get it home, but will not drive it until I replace with full threaded plugs and torque down those new plugs properly.

great video. Thanks for the update!

thank you for sharing your vast knowledge on this subject, you definitely saved me $$!

From an old toolmaker you are correct in your evaluation. The guides for the Cal-van reamer and tap are a big key to it being the best fix. Shame and double shame on Ford. I never had a lick of trouble with my Ford 460s. Question: I have a 2007 Class A Winnebago on the F53 Chassis which I assume is a 3 valve. Do you think I have to worry?

2-valve 4.6 owner reporting in. Ours throw plugs too. Still love mine though

Thank you for being so helpful! i really appreciate it. thank you that is very good information

Literally starting looking for videos because of the 4.6 so ya your right. I'll pay 220 instead of a 60 dollars kit when I know it'll be a lasting fix.

4.6's don't blow plugs?.....LOL, I had two and they both blew out plugs....

I see it all the time, very informative

Fantastic! Very good info, thanks for sharing.

Thank you for your video's. Very well done and helpful!!!

Thank you Ron you're great.

Just curious, since you already have those heads off will you go ahead and install inserts in all 8 cylinders?

Thank you very much for the video.

Great video i can handle this repair myself now thank you

Another awesome video Ron

I found this vid later and am repeating a post from the 2016 vid. I have a 97' e150 (174K) & 98' f150 (255K) both have 4.6L with aluminum intake and four wire per coil pack w/ plug wires. Plugs are tight. According to some reading and vin numbers each engine is Windsor with the earlier Non Performance Head. Was there a process change on the subsequent design w/ coil over plugs and plastic intakes tapping fewer threads and going cheaper? Thanks for the videos.

The centering sleeve on the Calvan is absolutely necessary to get the tools centered.

Just happened to tune in. I think you clearly explained the problem, especially helpful was the actual head showing the limited-depth spark plug holes. Man, Ford screwed up. This is why people like me, who prefer to support American made cars, have had to go Toyota and Honda which are at the top with respect to reliability. If I owned one of these Ford vehicles with this motor in it, and I wanted to keep it as long as possible, I would modify all plug holes with the tool you are recommending. Four thread only? That is both scary as the owner, and incompetent of Ford. Nice vid.

My 99' Crown Vic has lost 3 plugs in its life time but has 4 inserts in it. It lost one during its time as a police car, my dad lost one when i was about 16 years old. Then i lost one 10 years later. Man that cars been in the family for a long time. Its 1-2 shift is so hard it breaks the rear loose every time hahaha likes to hang out at redline for a second too before shifting when youre at WOT. Its been that crazy since the day my dad bought it from the Ford dealership (as a retired cop car). Ill never sell it lol

I agree with you 110%!!!

Nice video. Now I know to avoid the kamikaze kit. Here is a weird story. I’m no mechanic but I will try. A few years ago my father's 1998 F150 4.6 blew the number 4 plug out. Talked to a couple mechanics and without hesitation they all told me the treads were blown out. Did some internet research and got the same story. So, I bought a Spark Plug Rethreader Kit from NAPA (kamikaze kit as you called it) and was ready to install it. I had noticed that the plug that blew out (it was still on the wire) had some goop on it but as I said I’m no mechanic, so I ignored it. Decided to buy an endoscope (as that is not the easiest spot to look into) so I could make sure it was clean. Well, I get in there and it appears that the last guy to change the plugs had a problem with number 4 and used Loctite (or something) to glue the plug in. Whatever he did it worked for several years before it blew out. Anyway, the threads looked fine. I returned the kamikaze kit and picked up 8 of the recommended plugs, changed them all and have had no problems.

Awesome job. I have a 2003 Ford explorer. 4.6L. I've been driving my explorer for 2 years with a missing spark plug.

Thankf for these videos now I have a 2000 E250 with #7 blow out from a cheaper solution repair (Not Napa / Dorman) so now the plug hole exceeds 16mm as the step tap from the Chinese made repair kit that I have goes through w/o grabbing even one thread, actually I almost dropped it inside the piston. Can this repair be done again (Second Chance / Last chance) at 18mm with better quality and larger insert?

About 5 years ago my Town Car developed a tick noise with 280k miles on it on cold start up but would go away after the engine warmed up. I thought it sounded like a bad lifter of an exhaust manifold leak. Turned out #3 plug was loose but did not eject. I tightened it and to this day it's fine, no thread repair needed yet and has not come loose again. My kids car a Crown Vic started to make some noise and he ignored it. The plug ejected and damaged the coil in #1. We used the CalVan kit to repair it. He tells me after it was fixed that it's the e quietest it has ran for a long time. I always told him not ignore noises! He said he drove it for months making the noise before it blew out.

Your videos on the Ford spark plug ejection problem have been very helpful. My Calvan kit arrives tomorrow, and I have two questions. My 5.4 in a 2008 E350 has 8+ threads in each plug hole, something none of your videos have addressed. Please give me guidance for Calvan installation in the 8-thread holes. What is the part number of the two-liquid JB Weld product that you are now using?