ATV Florida Forum

The coil pack and plug blew out of the head on my '97 Expedition 5.4, 4x4.   Of course it was the next to last cylinder back so its under the firewall.   Everything I see is $500+ for the special tap tool sets, and what folks are posting with not always good results.   Of course my local dealer says we have to replace the head which requires taking the body off the frame to accomplish, and about 3 thousand minimum.    Is there an easy fix, or just time to part it out.  I've had the truck for 11 years and it has 250000 miles.

you could pick up a used head on car-parts.com for cheap but youl still need to pay labor or do the job. im no ford guy but this seems to be a somewhat common problem, it seems plenty of people try the repair kit with success. its only around 250 bucks, thats worth a shot to save 3,000 bucks if you ask me. i really dont see any other options, epoxy a spark plug in and drive it strait to the dealership for trade in lol.

is there enough room to heli-coil the hole?  If you think there is and are not familiar with repairing with heli-coil, do a google search for heli-coil repair-that would be as close to a permanent fix as you could get without replacing the head.  I've worked in srvc at a Ford dealer and a truck dealer at that for almost 5yrs and fortunately have not run into this problem on an expedition on-knock on wood.  Until I started searching the internet for an answer to your question I hadn't even seen a body off of an Expedition for engine repairs.....

http://www.denlorstools.com/autoblog/2009/01/expedition-cylinder-head-removal-body-off/

I would definitely say it might be time to part it out.  That is if the only option is to replace the head and removal of the body is absolutely necessary.  The repair might get to and over what the vehicle is actually worth, so it might be time to say goodbye to it.  If going forward with the repairs, a good reputable place and good prices to get the cyl head if that ends up being what it takes-we have used this company many times over and have had nothing but good results....

http://www.nationalcylinderhead.com/

-Although I do remember having a hard time getting our hands on a 5.4L cyl head the last time we needed one-might be long shot but worth the effort.

I will talk to some of the guys at work tomorrow and see if they have run into this or have any other ideas and will post up again tomorrow.

Mark

As far as a common problem, a spark plug that blows out of the head is usually a result from an improperly torqued spark plug.  I've seen it on 4.2L, 4.6L, 5.4L and can usually be traced back to the customer that had a coil over tune or tune-up performed in the not to distant past done elsewhere.  Engine vibration+compression+loose spark plug=bad day.

You should be able to repair it with out head removal Time Serts are the preferred repair,Check some local garages they may have the kit on hand & be able to fix it,If you are not experienced at thread repair I would let a experienced pro fix it you only have 1 chance to fix it right,check the forums at www.f150online.com

     Thanks Guys, appreciate the input.   About a year and a half ago a ticking noise started on that engine bank when cold, my mechanic said it was a small crack in the exhaust manifold, but in reading about the plug blow outs on these Triton engines it seems to be the precurser of the blow outs.
     Think I'm gonna buy an inexpensive truck, and take some time and pull the body off to repair it>

they make a repair kit for this problem in the single overhead cam 4.6 and 5.4 V8's it comes with a insert and new spark plug and a shorter boot for the coil its around 60.00 at the local car quest or napa I have done this repair to a customer car and it works and you dont have to pull the head.

Thanks, just called Carquest, $65 in stock.  Gonna go take a look to see how it works and give it a shot.   Thanks!

Just finished installing the Carquest kit, took about 30 minutes.  Lugnuts you 'da bomb.

If I went to the dealer      $3000++++

Carquest head repair kit    $65

Friends on ATV Florida to steer you in the right direction   PRICELESS

 :ThumbsUp.gif glad I could help look me up if you ever need anything!

He's pretty good with a quad too.   ;)

ARRRRRRRRRRGH!!!!!!!!!!!   Went to Subway, and went to pul out and rop, rop rop rop, figured I blew the head tap out but NOOOOOOOOO!   the tap in the #2 cyl left side was fine, blew the plug and coil off #3 on the right side.   If it wasn't for crap luck, I wouldn't have any!

If there is a bright side, you now know how to fix for less than 3K.

Yup, thanks for the smile.  ;D  $65 for the kit, $65 for the coil, $5 for the JB Weld, 8 or 10 cuss words from a guy who doesn't cuss, a day missed from work, and hopes it ends at 2, if this is a pre-curser it's time for a new truck!