NHTSA Complaint #10247144 — 2004 FORD F-150 ENGINE AND ENGINE COOLING:ENGINE

Complaint Details

ODI Number	10247144
Vehicle	2004 FORD F-150
Component	ENGINE AND ENGINE COOLING:ENGINE
Date of Incident	October 26, 2008
Date Filed	October 29, 2008
Mileage	41,000 miles
Crash	No
Fire	No
Injuries	0
Deaths	0
Vehicle Towed	No
State	FL

Consumer Description

FORD MOTOR COMPANY HAS DESIGNED A DEFECTIVE HEAD DESIGN THAT CAUSES SPARK PLUGS TO GET STUCK IN THE HEAD WHEN SERVICE IS ATTEMPTED. THE 100K MILE INTERVAL IS TOO LONG, EVEN SUB 50K MILES IS UNACCEPTABLE. THE CARBON BUILDUP AROUND THE LONG 2 PIECE SPARK PLUG CAUSES THE LOWER, CRIMPED ON PART TO STAY IN THE HEAD WHILE THE TOP 2/3 AND ELECTRODE COME OUT WHEN CHANGING THE PLUG. THIS DESIGN HAS BEEN PUT IN USE FOR 4 YEARS ON ALL 5.4L 3VALVE MOTORS. FORD HAS A TSB THAT ACKNOWLEDGES THE PROBLEM, BUT THEIR REMEDY STILL DOES NOT HELP. ONCE THE PLUGS, BROKEN AND UNBROKEN, ARE REMOVED, PUTTING NICKEL ANTI-SEIZE ON THE THREADS STILL DOES NOT REMEDY THE ISSUE BECAUSE THE THREADS ON THE PLUG ARE NOT WHAT IS STICKING. THE LOWER PART OF THE SPARK PLUG IS WHAT CAUSES THE TROUBLE. FORD HAS EVEN DESIGNED A TOOL TO REMOVE THE OFTEN BROKEN PLUGS. THIS JUST RIDICULOUS AND A SOLUTION NEEDS TO BE MADE BEFORE A VERY LARGE CLASS ACTION SUIT IS DRAWN UPON FOMOCO. *TR

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