Triton 5.4 2V spark plug issues

Hi All

Has anyone here ever re-sleeved a 5.4 spark plug hole?

I'm looking at a truck with said engine, and I'd like to know what I'm in for if I run into this issue.

Recommended sleeve kits? What to stay away from?

Thanks in advance.

I've had a 4.6 re-threaded twice, which is the same head as the 5.4. Have a professional do it, because if you berk it up it's cheaper to buy a complete engine than the replacement timing chain and gasket set. It's a timesert setup.

In reply to akamcfly:

In 2003 Ford fixed the heads with 8 thread spark plug bosses. Earlier heads only had 4 threads so plug blow out is a common problem from 2002 and back. Most people just put a timesert in it and keep them torqued properly.

www.fordtrucks.com forums will let you the best kits. One MFG for at home repairs and another is best for on the side of the road repair but for the life of me i forget who as my 6.8 is new enough i should not have to worry...

I think the last one I did I just used the kit that Car Quest had in stock. It's held up just fine.

akamcfly wrote: Hi All Has anyone here ever re-sleeved a 5.4 spark plug hole? I'm looking at a truck with said engine, and I'd like to know what I'm in for if I run into this issue.

They suck to do.

GoFastr wrote: In reply to akamcfly: In 2003 Ford fixed the heads with 8 thread spark plug bosses. Earlier heads only had 4 threads so plug blow out is a common problem from 2002 and back. Most people just put a timesert in it and keep them torqued properly.

So I'm most likely ok with the 2003 I'm considering? Or was it a change in 03 for MY04?

In reply to akamcfly:

The problem is when Ford "fixed" the thread engagements, they messed up the plugs. The MY 04+ 5.4's have a multi-piece plug that's a POS and breaks off in the head. There's even a class-action suit that Ford lost.

MY03 still has the 4-thread engagement heads.

Well thats a different problem and theres a different tool for it too. I've not done one yet but as i understand it the fif is to punch through the plug then use the toll to remove the colapesed shell. Yes it sounds like a real pain in the a$$

Is this problem a deal breaker? I could sure use this truck and the price is right.

i've HEARD information all over the map.

my EXPERIENCE has been, that the 2-valve mod motor heads always have too-few spark plug threads. more than one person has told me they were updated to correct the problem in ~2003. i've never seen an example in real life. including my own 2005 production date 2-valve 5.4

what did happen in ~2004, is that the 3-valve head became available in some applications, and it's associated stuck/broken spark plug problems.

akamcfly wrote: Is this problem a deal breaker? I could sure use this truck and the price is right.

absolutely not

I used the time-sert system in a 4.6 and it worked great. Didn't have an issue after 50k additional miles at least.

If you need to rent the tool let me know.

The threads coming out and ejecting spark plugs is a problem with the 2v engines, and the spark plugs breaking off in the head is a problem with the 3v engines. That being said, I've only personally seen the thread problem on early 5.4L 2v engines. I think the newest one was an '01, so maybe they did make them a little better after that.

akamcfly wrote: Is this problem a deal breaker? I could sure use this truck and the price is right.

It was for me, personally, when truck shopping, due in no small part from having my 01 P71 drop two plugs. That weariness is certainly reflected in resale values as well.

Blown Spark Plug, 2002 Ford E250 Cargo Van, 5.4L Trition, tow vehicle. 121,884 miles. I purchased it used about 10,000 miles ago.

Did everything it should and I was very happy until the other morning when I started it up. Immediately sounded like I blew a hole in the exhaust, but thing was, it ran rough and as soon as I put it in gear it was clear I was only running on 7 cylinders... So shut it down. Checked under the hood, then pulled the cowling in the passenger compartment. Found something did not look right with number 2 cylinder. Coil was out of place. Well lucky me, I have a blown out plug and it broke the mounting ear on the coil as well. Turns out this is a very common problem with 1998-2002 Triton engines. Bad head design that only has 4 aluminum threads holding in the spark plugs...

Did some research on the web, and IMHO the best fix is the Time-Sert kit. But lacking $400, and needing the van now, I came upon the Dorman 42025 kit at Advance Auto Parts. Right or wrong, this kit is what I used. It includes a tall threaded adapter which is also a tap, a shorter coil boot, and the new style 2003 and up spark plug. You can see it here. http://www.youtube.com/watch?v=cE8EqpmePik

Also I bought my coil on ebay. Given the cost of just one locally, I got 8 delivered to my door for $58 http://www.ebay.com/itm/NEW-GLOBAL-AUTOMOTIVE-IGNITION-COIL-FORD-LINCOLN-MERCURY-DG508-SET-OF-8-/150941922000?pt=Motors_Car_Truck_Parts_Accessories&hash=item2324d6f2d0

So after removing the coil and picking up the spark plug near the fuel rail. I used compressed air to blow anything that might be in the cylinder out and proceeded with the install. I have to admit I was skeptical, but so far so good, I found one post in another forum of someone who installed this same kit 10 months ago and all is still good.

I am going to purchase a second kit to keep in the van with tools, as you could literally do this by the side of the road. Can't afford to have the heads redone, and can't afford to replace the van so this is the best option for me.

Best Regards, Don

Canoe?