Log In | Register
Skip to main content
Topic: Spark Plug Blowout (Read 11 times) previous topic - next topic
0 Members and 1 Guest are viewing this topic.
Spark Plug Blowout
Yahoo Message Number: 88738
Most of us have probably heard about spark plug blowout on the Ford modular engines, including the Triton V-10 in the late model Lazy Daze. There is a lot of discussion on the Internet and this issue recently made it into Motorhome magazine. Unfortunately I haven't been able to locate the reports that were in Motorhome, so haven't read those, but I have done considerable research on the Internet and have corresponded with Steve at LD and the folks at blownoutsparkplug.com.

I think we all know that the Internet can be a great source of information but also hysteria. Here is what I've learned, what I've concluded and what I'm going to do.

My sense is the problem is quite small and occurs much more often on the V-10s produced in the late 90s. Steve said he's only aware of two blown plugs among his many customers, both on the late 90s chassis. At the Ford Truck Enthusiasts forum there are a couple of surveys of the members there. They showed less than 5% had had this problem and my sense is that those threads would be skewed toward folks with the problem, who are searching for a solution and so end up there. There are some "consumer" sites where people can "sign" on-line petitions about this issue. Scanning those entries shows many more late 90s vehicles. And it is important to note that very few entries I came across on all these sites were for motorhomes or vans, but of course there are fewer of those.

Nonetheless, it seems to me that there clearly was a problem with either the design or assembly of this engine. Ford made some changes over the years to address the problem but it is hard to get reliable information as to exactly what was done when and how effective it was. What is clear is that Ford eventually introduced a redesigned spark plug and increased the depth of the spark plug threads in the heads. The latter change was supposedly made for the 2003 model year but it is hard to pin down exactly when due to vagaries of the production process. For instance, my chassis was built in May, 2003 but the guy at blownoutsparkplug.com says it may well have the older heads.

I'm not going to speculate about the cause of this problem because my conclusion is that no one knows for sure. Somehow, plugs loosen and then blow out, often taking the on-plug coil unit with them. Repairs can be made. Ford apparently prefers new heads.
Several thousand dollars. But there is ample evidence that simpler repairs are effective. All involve inserts in the damaged plug hole into which a new plug is installed. There is a Ford approved hardened aluminum insert. But there are also many reports of good results with Timeserts and with whatever blownoutsparkplug.com does. While some support helicoils others say no to those. Why take a chance? Whatever the approach it seems wise to have the work done by someone who's done it before and has had success.

You can apparently drive more or less safely with a blown out plug, to a point of repair, for instance. Disconnect the coil pack and the corresponding fuel injector. blownoutsparkplug.com sells an emergency kit that you can use to plug the hole, although that apparently isn't essential.

There also is a lot of encouragement out there for more frequent spark plug changes, inspections and periodic retorque of plugs.
I've not seen it in writing from Ford, but supposedly they now recommend plugs changes or at least inspection and retorque every 30K miles, instead of 100K as stated in your owner's manual.

So, what am I going to do? Well, my guess is that with my 2003 Ford V-10 I could just ignore all this, follow the manual and change plugs at 100K. But I'm not going to do that. My E-450 has 50K miles on it, halfway to the normal change. On my way to Baja early next month I'm going to blownoutsparkplug and am going to have them change my plugs. That will cost $400. Ouch!

It's not easy to get to these plugs and a plug change is not routine. They have the right tools and have done this many times.
Cleanliness is important and they clean the plug holes well before installing the new plugs. They use more torque than Ford specifies. But from all indications they get excellent results.

And they will determine which heads I have. If I have the later heads then I will quit worrying about this and have the plugs replaced again at about 125K. If I have the old heads then I may get some sort of recheck or another replacement at about 100K.

My theory here is that the true cost of this will be $200, since it would normally be done at 100K for the same $400. To me, that's a small price to pay to address one of the few known potential weak points of this engine. My E-450 has been a very reliable vehicle and I've spent little other than on routine maintenance.
To me this is sort of like an early tire change or an early brake job to be assured I don't and won't have a problem in this area.

As far as I can tell this became a non-issue on 2004 and later models. 2003 was a transition year, maybe a problem, maybe not.
From that point back this is increasingly likely to be an issue, especially in the 90s models, though never a big one. I encourage you to do your own research and decide what your strategy will be. Your choices range from doing nothing on up to having blownoutsparkplug preemptively install inserts in all ten plug holes, which they've done for some customers, like emergency vehicle operators and worry wort motorhome owners.

One final note. Over on the Techsnoz site Terry Tanner has some information about how to change your own plugs, which many have done. I'd do research elsewhere too, though, before doing that. There is some controversy about whether to use anti- seize on the new plugs, for instance.

Terry

2003 26.5'RB
Gardnerville, NV
Terry
2003 26.5'RB
Gardnerville, NV
 
Re: Spark Plug Blowout
Reply #1 –
Yahoo Message Number: 88756
On my way to

Quote
Baja early next month I'm going to blownoutsparkplug and am going to have them change my plugs. That will cost $400. Ouch!
Well gee Terry, that sounds like a pretty good deal to us. We just had our local Ford garage do ours at 60,000 miles in preparation for Baja and it cost us $450. Plus they broke the passenger cabover window getting it out of their rack. We're still in the process of having them fix that one(at their expense of course). By the time we meet you in Chula Vista I may be able to laugh about this, but not quite yet.
Mary & Ron Tribbett Dixon, CA