NHTSA Complaint #10314550 — 2005 FORD F-150

AT JUST OVER 59K MILES ON MY 2005 F-150 5.4L TRITON V8 DRIVING AT 30 MPH I NOTICED A TICKING SOUND THAT INCREASED/DECREASED WITH RPMS. TRAVELING ABOUT 2 MILES FURTHER THE NOISE INCREASED IN VOLUME SO I PULLED OVER AND RAISED THE HOOD. THE NOISE WAS COMING FORM THE PASSENGER SIDE OF THE MOTOR AND THE MOTOR WAS SHAKING AS IF MISS FIRING OR RUNNING IRATICLY. I HAD NO ENGINE WARNING LIGHT OR ANY OTHER NOTIFICATIONS ON THE DASH PRIOR. I WENT DIRECTLY TO MY MECHANIC. WHEN MY MECHANIC CAME OUT TO SEE WHAT WAS HAPPENING HE KNEW RIGHT AWAY WHAT WAS GOING ON. HE HAS REPAIRED THIS PROBLEM SEVERAL TIMES BEFORE. HE SAID THAT I HAD BLOWNOUT A LEAST ONE SPARK PLUG. THIS IS A KNOWN FLAW WITH THE TRITON V8 MOTORS OR RATHER THE SPARK PLUG DESIGN THAT WAS PUT IN THE ENGINE FROM THE FACTORY. THE SPARK PLUG IS A THREE PIECE DESIGN THE IS CRIMPED TOGETHER AND ULTIMATELY CRACKS AND SEPARATES OVER A PERIOD OF TIME LEADING TO LITERALLY BLOWING UP. IN SOME CASES THE THREADS IN THE MOTOR WHERE THE SPARK PLUG SCREWS IN CAN BE TORN OUT. THIS REQUIRES RE-TAPPING NEW THREADS OR A HELIOCOIL PACK. THIS ISSUE WAS NOT POINTED OUT TO ME BY FORD PRIOR SO I COULD PREVENT POSSIBLE DAMAGE AND VERY EXPENSIVE REPAIR COSTS AS I KNOW THEY ARE AWARE OF THIS PROBLEM AND THAT IS VERY WRONG. THE MANUAL PROVIDED BY FORD WITH THE TRUCK SAYS THE SPARK PLUGS DON'T NEED TO BE CHANGED UNTIL 100K. AFTER FURTHER INVESTIGATION ONLINE I FOUND HUNDREDS OF OTHERS EXPERIENCING THE SAME PROBLEM PRIOR TO 100K. I WILL BE SENDING THE BILL TO REPAIR MY TRUCK TO FORD THROUGH MY ATTORNEY AS THIS IS NEGLIGENT BEHAVIOR AND A FAULTY DESIGN FLAW THAT I COULD NOT HAVE PREVENTED. FORD IS SENDING OWNERS OF THIS MOTOR DOWN A PATH OF GUARANTEED FINANCIAL AND POTENTIAL PHYSICAL HARM. FORD NEEDS TO STAND UP AND OWN THIS MISTAKE. *TR