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Topic: Blown spark plugs- 2003 and earlier V10s (Read 428 times) previous topic - next topic
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Blown spark plugs- 2003 and earlier V10s

Ford's V10s, up until the middle of the 2003 production year, have problems with the spark plugs blowing out.
The cause was having too few spark plug threads and plugs that were being torqued, during manufacturing,  at too low a setting.
Our 2003's plugs were changed at around 80,000 miles, two of the plugs were found to be finger tight.
It was a near blow out.

So, if your V10 suffers a blowout, there are several ways to fix the problem.
Most common is a threaded inset but this requires specialized equipment and a experienced tech.
If the blow out occurs 90 miles from nowhere you have a few choices.
-You can wait for a tow truck and get hauled into the nearest major town, with a qualified mechanic. This might take a while.

-You can pull the doghouse and Install the Blowsparkplug plug, that you were so smart to have bought ahead of time.
While you are at it, you must disconnect the remains of the coil and also find and disconnect the fuel injector for that cylinder, to prevent destroying the catalytic converter.  Once everything is back together again, drive to the nearest qualified mechanic and have the cylinder head repaired.
The engine will run OK on 9 cylinders but it isn't something you want to do for extended periods.

-The last solution is to remove the doghouse and install a spark plug repair kit that will restore the engine to full power operation.
Here is a solution that works, we used it on a friend's LD, after it spit out a spark plug.
Dorman 42025 spark plug thread repair kit.
Blown spark plug repair kit | Flickr
Amazon.com: Dorman 42025 HELP! Cylinder Head Repair Kit: Kindle Store
The coil can be damaged or destroyed if a plug blows out. Carry a spare to go along with the repair kit.

Using the kit requires no more work than using the temporary plug. The doghouse must come off when using either
method.
If you own one of the older V10s, with the old head, it is a good idea to check the torque on the plugs.
The original torque was 12-lbs and now the recommended torque, according to the techs at Blownsparkplugs, is 28-lbs.

Larry

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Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
 
Re: Blown spark plugs- 2003 and earlier V10s
Reply #1 –
When we got our 98~MB last year it had 74K miles on it, at 80K we pulled all of the plugs and replaced them with new plugs and toked them to the now re comended value of 28 ft lbs.  At least one if not two plugs were finger tight.  We think that they had last been done around 50K, they looked good.  I chose to change the plugs biased on what I read here in LDO and had down time for the LD so it made sense.

     Karen~Liam
        98~MB
1998 ~ MB  WanderDaze
previously a 1984 Winnebago itaska- The Road Warrior, before that several VW Buses and before that a 1965 Chrysler Convertible Newport or our 1969 Chrysler La Barron with an ice box and a couple sleeping bags
Re: Blown spark plugs- 2003 and earlier V10s
Reply #2 –
Quote from: Karen & Liam  - 
  At least one if not two plugs were finger tight.  We think that they had last been done around 50K, they looked good.  I chose to change the plugs biased on what I read here in LDO and had down time for the LD so it made sense.
For the few 2003 or earlier V10s,  whose plugs have not been changed yet, it is a very good idea to change the plugs before the  recommended 100,000 mile interval.

Too many of the spark pugs have been found loose and a few have blown, an expensive and inconvenient repair.

Changing the plugs is within the range of an advanced shade tree mechanic. There is nothing that is too complicated but it is a big job that will take most of a day.
V10 Spark plug change | Flickr
planning to remove the doghouse for SparkPlug chgange- what should we look for?

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: Blown spark plugs- 2003 and earlier V10s
Reply #3 –
"For the few 2003 or earlier V10s,  whose plugs have not been changed yet, it is a very good idea to change the plugs before the  recommended 100,000 mile interval. Too many of the spark pugs have been found loose and a few have blown, an expensive and inconvenient repair."
----
The plugs in my 2003 were changed at 87k by Blown Out Sparkplug in Santa Ynez; they used OEM parts. The plugs were seated in 8-thread holes (engine manufacture date stamped on the head was 27 May, 2003). One plug was slightly loose, but all were in good shape and "un-carbonized", the boots/coils were good, and the wells were also clean. The plugs were torqued per BOS specs. Not cheap at $400, but necessary preventive maintenance, and not a job that I could myself.
2003 TK has a new home
Re: Blown spark plugs- 2003 and earlier V10s
Reply #4 –
How common is this problem? I had heard of it so when I bought my unit I had the plugs checked. With my mileage I wanted to be sure the plugs had been replaced and torqued to spec. Everything was good.
Lynn and Lori
Re: Blown spark plugs- 2003 and earlier V10s
Reply #5 –
How common is this problem?
---
I have only anecdotal information, but no statistics. My personal experience was with my 2003 with a build date of May 27, 2003 stamped on the head. The plugs were seated in 8-thread wells; the tech at BlownOutSparkPlug in Santa Ynez said that the May 27 date was the earliest he had seen for 8-thread wells in the E450.

I have no idea what the magic "switch from 4 to 8 threads" date is, but going only from the BOSP tech's experience, it seems logical that a rig with a build date prior to late May, 2003, could have 4-thread plugs. For rigs manufactured earlier, IMO, it would be a swell idea to pull the head and check the plugs (and coils and everything else while the head is off).
2003 TK has a new home
Re: Blown spark plugs- 2003 and earlier V10s
Reply #6 –
Hi Duro, I'm hoping Joan meant 'valve cover'. Pulling the head off would be an extreme thing to do for a problem you may never have. RonB
RonB (Bostick) living in San Diego
Original owner of "Bluebelle" a '99 TKB
Re: Blown spark plugs- 2003 and earlier V10s
Reply #7 –
Quote from: JCT  - 
I have no idea what the magic "switch from 4 to 8 threads" date is, but going only from the BOSP tech's experience, it seems logical that a rig with a build date prior to late May, 2003, could have 4-thread plugs. For rigs manufactured earlier, IMO, it would be a swell idea to pull the head and check the plugs (and coils and everything else while the head is off).
Any V10, from the early 2000s, may have loose spark plugs, due to the lower plug torque used back then.
The only way to know for sure what head your LD has is to pull a plug and count the threads.
If you are going that far, continue and change all the plugs and tighten them to the higher 28-lbs torque.

As mentioned before, our 2003 had two finger tight plugs, when they were changed at 80,000 miles.
Knowing what know now, I would have check the plug's torque years earlier, as a preventative.

Larry

Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: Blown spark plugs- 2003 and earlier V10s
Reply #8 –
I'm hoping Joan meant 'valve cover'.
---
I did mean "valve cover"; my head was wedged! Sorry!  :(
2003 TK has a new home
Re: Blown spark plugs- 2003 and earlier V10s
Reply #9 –
Hi Larry. Would you use anti seize nickel paste on the threads of the spark plugs? At 43k and '99 I'll be checking the torqure on my plugs in the next few weeks.  RonB
RonB (Bostick) living in San Diego
Original owner of "Bluebelle" a '99 TKB
Re: Blown spark plugs- 2003 and earlier V10s
Reply #10 –
It is not recommended to apply anti seize unless it is a plug that has been repaired with a steel insert.  I had a cheap repaired insert shoot out last summer.  In the beginning of summer I had replaced all plugs and checked the torque.  I knew I had repairs on #4 and 10 cylinders.  I was able to thread the insert back in with the plug and spent some time with blownoutsparkplug.com and asked many questions.  With 220k she runs well.
1997 TK
Re: Blown spark plugs- 2003 and earlier V10s
Reply #11 –
Quote from: RonB  - 
Hi Larry. Would you use anti seize nickel paste on the threads of the spark plugs? At 43k and '99 I'll be checking the torqure on my plugs in the next few weeks.  RonB
Nope, the plug's threads are already treated.
While the plugs are probably still in good shape, at 49K, the rubber boots may have deteriorated, due to age.

It's a fun job getting to the plugs. It is a lot easier if you unbolt the seats and push them rearward.

Larry

Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: Blown spark plugs- 2003 and earlier V10s
Reply #13 –
"It's a fun job getting to the plugs."
----
 ;)  In an "old" TK, the the intrusive doghouse is a PITA to work around and seats, particularly the driver's seat, which is smack up against the bathroom, are not easily moved. More work space would definitely be more comfortable, but the plug guys said they could manage; they did. (I stayed out of their way, but watched the whole process.)

One thing that may not be important for others is that there can be dirt and sand and whatnot visible when the doghouse is removed, so, before replacing the doghouse, they air hosed out all the debris at my request.  (Not quite channeling Tom R., but one does like a tidy rig! :D )
2003 TK has a new home
Re: Blown spark plugs- 2003 and earlier V10s
Reply #14 –
Quote from: JCT  - 
"It's a fun job getting to the plugs."
----
 ;)  In an "old" TK, the the intrusive doghouse is a PITA to work around and seats, particularly the driver's seat, which is smack up against the bathroom, are not easily moved. More work space would definitely be more comfortable, but the plug guys said they could manage; they did.
With air tools, the seats take less than a minute each to unbolt. It's well worth the effort for us shade tree mechanics.
With the seats out, you can comfortably sit on the floor.
8 of the 10 plugs are removed from the inside of the cab, so you will be spending a bit of time there.

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze