NHTSA Complaint #10082335 — 1998 FORD F-250

WHILE STARTING MY FORD TRUCK WITH THE 5.4 L ENGINE I HEARD A VERY LOUD POP AND THE ENGINE RAN AS IF THE HEAD GASKET BLEW. A NON-FORD MECHANIC VERIFIED THE NO. 3 SPARK PLUG ON THE PASSENGER SIDE BLEW OUT AND STRIPPED THE THREADS FROM THE CYLINDER HEAD INSERT THAT THIS FORD DEALER INSERTED TO REPAIR AN EARLIER BLOWN SPARK PLUG. THE OLD INSERT FOR THE PREVIOUS FAILURE WAS REMOVED AND REPLACED WITH A NEW TYPE ACCORDING TO THE FORD MECHANIC. THIS IS THE SECOND TIME FOR THIS TO HAPPEN. ON JULY 10, 2003, APPROXIMATELY 1 YR AND 2 DAYS BEFORE THIS FAILURE THE NO. 3 SPARK PLUG BLEW OUT STRIPPING THE TREADS IN THE CYLINDER HEAD. NUMEROUS NON-FORD MECHANICS I'VE TALKED TO HAVE VERIFIED THIS BEEN A FAIRLY COMMON OCCURRENCE IN THE 5.4 L FORD ENGINE IN TRUCKS AND SUV'S. AN INDIVIDUAL THAT I WORK WITH HAD THE SAME SPARK PLUG (NO. 3 PASSENGER SIDE) BLOW OUT FROM HER FORD EXPLORER WITH THE 5.4 L ENGINE APPROXIMATELY 6 WEEKS AGO. *LA