Spark plug Threads melted

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Pogo - 22 May 2008 06:39 GMT

Hi All,
Looking for possible solution,
2001 F-150 Smaller V8 "4.8L", "Triton". Driving the vehicle underload
"Camper" heard what I though was a loud exhaust leak!
Inspection showed that the coil on passenger side/3rd fromt front was
dangling on top of the engin block...not a good sign..

Turns out that threads are striped and hot gases melted the remaining thread
to mount spark plug. I had a local chap come by and re-tap the thread and
install a Helix-Coil ?. Have not fired the engine up yet as two things are
not certain. 1).Turned engine (without spark) over with new plug in place
and a slight leak still present between helix and old thread - not good. 2)
how long will this type of patch maintain itself?

I would like to add some type of putty material that could harden would
assure a proper seal to this new fix. Can I use a material in conjunction
with a spark plug that has a compression washers to further prolong the
inevitable...replacement of the head. As this truck has many miles on it
~135k I don't see that value in spending $2000.00 in fixing it. Would like
to keep it runnin after a fashion for use on the farm.

Your thoughts.

Marc

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Rodan - 22 May 2008 07:25 GMT

"Pogo" wrote: ( 2001 F-150 4.8LTriton V8)

A spark plug on the passenger side (3rd from front)
blew out because the plug hole threads had stripped.
A friend re-tapped it and installed a Heli-Coil.

I cranked the engine (without spark) with a new plug
in place and a slight leak is still present between the
old thread and the Heli-Coil.

Can I seal the leak with some type of hardening putty
in conjunction with a spark plug that has compression
washers?

=======================================

No sealant needed. Buy or make a copper washer
with an OD a little larger than the OD of the Heli-Coil.

Note: There are probably metal chips in the cylinder
from the Heli-Coil tapping. This may cause problems.

Good luck.

Rodan.

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Pogo - 22 May 2008 07:56 GMT

Will consider the copper washer.
took great care not to get metal chips in cylinder, copious amounts of
grease injected in cylinder cavity scooped and flushed out after heli-coil
install, though there is a risk of contamination.

> "Pogo" wrote: ( 2001 F-150 4.8LTriton V8)
>
[quoted text clipped - 21 lines]
>
> Rodan.

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C. E. White - 22 May 2008 12:47 GMT

> Hi All,
> Looking for possible solution,
[quoted text clipped - 22 lines]
>
> Marc

Helicoils are not a good repair for this failure. Ford has authourized
only one type of insert -

----

Engine - Cylinder Head Spark Plug Thread Repair

TSB 07-15-2
08/06/07
5.4L 2V AND 6.8L 2V MODULAR ENGINE SPARK
PLUG THREAD OUT OF WARRANTY REPAIR
PROCEDURE FOR ALUMINUM HEADS
FORD:
1997-2000 F-250 Light Duty
1997-2003 F-150
1997-2004 Expedition
1997-2007 E-Series
1998-2004 F-53 Motorhome Chassis,
F-Super Duty
2001-2005 Excursion
LINCOLN:
1998-1999 Navigator

ISSUE
Various 1997-2007 vehicles with a 5.4L 2V, or 6.8L 2V engine with
stripped or missing spark plug port threads in modular engine aluminum
heads. Ford Motor Company now authorizes LOCK-N-STITCH aluminum
inserts and tool kit.

ACTION
Follow the procedure included in the tool kit for using the tools and
inserts. Tool kits and inserts can be ordered from Rotunda by calling
1-800-Rotunda (768-8632). Choose option two (2), number 302-00001.
NOTE FORD MOTOR COMPANY HAS DETERMINED THAT REPAIRS MADE WITH THESE
ALUMINUM INSERTS AND LOCK-N-STITCH TOOLS DO NOT AFFECT THE HEAT
TRANSFER FUNCTION BETWEEN THE SPARK PLUG AND THE CYLINDER HEAD.
NOTE THIS PROCEDURE IS NOT AUTHORIZED FOR WARRANTY REPAIRS AND IS THE
ONLY FORD AUTHORIZED PROCEDURE FOR SPARK PLUG THREAD REPAIRS.
WARRANTY STATUS: Information Only - Not Warrantable

----

Others have recommended the Timesert Kit

http://www.timesert.com/html/ford.html

If it was my engine, I'd install the Timesert Kit.

Ed

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