NHTSA Complaint #10392544 — 1999 FORD F-150

ENGINE AND ENGINE COOLING:ENGINE issue reported to NHTSA

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Complaint Details

ODI Number	10392544
Vehicle	1999 FORD F-150
Component	ENGINE AND ENGINE COOLING:ENGINE
Date of Incident	March 22, 2011
Date Filed	March 22, 2011
Mileage	141,000 miles
Crash	No
Fire	No
Injuries	0
Deaths	0
Vehicle Towed	No
State	MO

Consumer Description

WHILE DRIVING 45MPH ON SUBURBAN TWO LANE HIGHWAY I HEARD A LOUD BANG AND SUBSEQUENT RHYTHMIC POPPING SOUND ACCOMPANIED BY AN ENGINE MISFIRING. UPON INSPECTION I FOUND THE # 4 CYLINDER SPARK PLUG LYING ON THE VALVE COVER; UN ATTACHED TO THE CYLINDER HEAD. THE MECHANIC FOUND THE THREADS "BLOWN OUT" OF THE HEAD AND HAD TO UTILIZE A HELI-COIL KIT TO REPAIR. THE SPARK PLUG WAS A MOTORCRAFT ORIGINAL EQUIPMENT PART. THIS SEEMS TO BE A PREVALENT PROBLEM WITH THE TRITON 5.4 LITER ENGINE. I SUSPECT THE PROBLEM ORIGINATING FROM UNDUE STRESS FRACTURES IN THE ALUMINUM HEAD AFTER CONTINUED USE AND INHERENT THERMAL DIFFERENTIAL RATES (EXPANSIONS/CONTRACTIONS) OF THE TWO DIFFERENT METALS; I.E. STEEL SPARK PLUG VS. ALUMINUM ALLOY HEAD. POOR ENGINEERING !! I AM THE ORIGINAL OWNER OF THE F150 WITH 140K MILES. *TR

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