I have a 200 Ford Expedition and the #3 plug blew out at 128,000 miles. From the research I have done on the internet, definitely a design problem from Ford. Does anyone know if Ford plans to re-call or reimburse for these repairs? It's costing me nearly $700 and no guarantee it won't happen again.

 

Had the same thing happen (No.3) to my 2000 5.4 expedition. SOB, 100 miles from home and I only had 70+K miles on it. No, dont hold your breath, Ford will not help you with this long known problem that has ruined many Ford believers. Cost me a whole bunch of money to fix it and I guess we can never be sure it wont happen again. I spent the money because I've had my Expedition since new, so 10 years and even though that pissed me off to no end, I love my truck. If I could put a 7.3 or a 5.9 diesel in it I'd keep it forever.

 

they make a part to fix this on ebay
Dorman 42025 Spark Plug Thread Repair Kit

 

I hear that that blow out business is common.

 

Mine did it at 80k miles. Yes, #3. I did a lot of research and decided on TimeCert insert kit. I bought it for around $550, fixed the hole with one of the 5 provided inserts, then sold the kit with 4 inserts for $450.

I would like to meet the weak design team that allowed so few threads in the final design that made it into production. This is an aluminum head, not cast iron - what were these idiots thinking? Yes, Ford should do something, but the recoil from it would be unacceptable to their warranty legal group. Thanks Ford. I bought a Camaro instead of a Mustang just for this exact debacle.

 

I derive no pleasure from saying this, but because Ford will not stand behind their products , the new vehicle I just purchased is not manufactured by Ford. I have to add the others of the big 3 are no better. That's why I purchased a different brand.

 

VERY Common. I've heard MOST 5.4L engines have this problem before 100k miles. It happened on my Expo and I sold it for practically nothing because I didn't want to deal with it happening again.

Good luck!