NHTSA Complaint #10104710 — 2001 FORD F-150

THIS IS A 2001 FORD SVT LIGHTNING THAT HAS BEEN A VICTIM OF A BLOWN SPARK PLUG. THIS IS A COMMON FAILURE IN THESE TRITON MOTORS. IN THE NEW GROUPS, IT IS SPECULATED THAT THIS OCCURS FOR TWO REASONS. 1) A DESIGN ERROR IN THE CYLINDER HEAD. IN THE PRE-2003 5.4 MOD MOTOR HEADS, THERE ARE A TOTAL OF 4 THREADS. FORD HAS REALIZED THIS PROBLEM AND CORRECTED THE 2003-LATER HEADS WITH 8 THREADS TO HOLD THE SPARK PLUG IN. THIS PROBLEM EFFECTED ALL TRITON 5.4 MOTORS AND THE PROBLEM HAS SHOWN UP IN 5.4 LITER MOTORS IN OTHER NON-LIGHTNING TRUCKS AND EXPEDITIONS. 2) THERE HAVE BEEN MANY INSTANCES WHERE FORD CUSTOMERS HAVE FOUND THAT THE SPARK PLUGS HAVE BEEN VERY LOOSE IN THESE TRITON HEADS. THIS IS NOT KNOWN WHETHER THIS IS FROM A LACK OF THREADS OR BEING LOOSE FROM THE FACTORY. EITHER WAY, IN THIS DAY AND AGE IN AUTOMOTIVE TECHNOLOGY, THE REQUIREMENT THAT A CUSTOMER HAS TO CHECK THE TORQUE ON SPARK PLUGS IS UNREALISTIC. OTHER FACTORS TO CONSIDER: MY LIGHTNING IS A 2001 MODEL WITH 15,000 MILES ON IT. OBVIOUSLY IT IS INFREQUENTLY USED. THERE IS A PERFORMANCE CHIP THAT DOES NOT ADD BOOST. IN ESSENCE, THIS TRUCK IS PAMPERED. THE HEAD FAILURE OCCURRED DURING NORMAL DRIVING ON A SLIGHT INCLINE GO THE SPEED OF TRAFFIC. APPROXIMATELY 35 MPH. THERE IS NO DETONATION ISSUES WITH THIS VEHICLE. PRIOR TO THIS FAILURE THE POWER TRAIN HAD NO CHRONIC ISSUES SUCH HAS UNKNOWN SUPERCHARGER NOISES, ENGINE TICKS/KNOCKS, IGNITION, FUEL ISSUES OR SMOKY EXHAUST. FORD WILL NOT COVER THIS DAMAGE AND FAILURE EVEN THOUGHT THIS HAPPENS FREQUENTLY IN F-150 FORD TRUCKS RUNNING THIS ENGINE. *NM