How To Repair A Stripped Spark Plug Hole On A 2002 Ford F150

WiseAutoTools.com © Summary: This is 1 of our more extensive articles on spark plug thread repair. If you demand answers fast to get a vehicle upwardly and running quickly we understand. No fourth dimension to read? We've got answers, give united states a call at 800-734-8665 x251. To go on some research by reading 10-15 minutes run across below.

Ford spark plug blowout repair using a kit over the fender. Most common engines that have the problem are Ford 4.half-dozen, 5.4 & 6.viii liter engines, although any engine tin can have this issue. If unsure of which spark plug thread repair kit is right for your engine, nosotros tin can assist. Simply requite Dennis a call (he'due south a Master Tech shown in the video beneath demonstrating the Time Sert 5600 kit). We have been helping Ford owners and repair shops with this common trouble since 2005. For more data on this repair, read on. Be sure to see the highlighted text for a brief rundown on our most pop kits and size holes the kits can be used on. You may also ask a question by using our Contact Class, be certain to permit usa know what y'all're working on. Please provide the twelvemonth, make model, size engine and outside diameter of the failed insert if y'all know – or allow usa know if this is a starting time time repair.

Call us! We're only a phone telephone call abroad – 800-734-8665. Read on for more info on how to prepare stripped threads due to spark plug blow outs. See the links below for the all-time kits to fix it yourself. These are considered "permanent" type repairs as opposed to the parts shop kits that just put a Band-Aid on the problem. Parts store repairs commonly blow dorsum out.

There are many unlike brands of spark plug thread repair kits on the market today for the common Ford spark plug blowout problem. The repairs are not all equal. We're familiar with the best thread repair kits and with some that unremarkably end up declining. Sometimes the lower stop kits blow out again while driving and sometimes the repair insert comes out with the sparkplug during a melody up. Since you're reading this, you may already know that some Ford dealers write repair estimates for thousands of dollars to replace the cylinder heads when a spark plug blows out. If your vehicle has had a quote like this: your research hither, volition be rewarded presently. We have many do it yourselfers purchase kits from us and practise the repair themselves. Some decide to purchase the kit and have their regular mechanic do the work. We likewise have many shops purchase kits after reading our information. Some Ford dealers are regular customers, after purchasing a kit they render for replacement inserts.

Our oversized spark plug thread repair kits set "parts shop brand" failures and can be washed in the vehicle, without removing the cylinder caput. Based on toll and results; the Calvan 38900, the Time Sert 5553 and the Fourth dimension Sert 5600 are the best thread repair kits on the market for fixing threads when an inferior kit has failed. We've had bang-up feedback on these kits since 2005! Based on our customer's feedback we know what works. Our kits come with steel alloy thread inserts which share similar properties with aluminum, so at that place's no issues with grounding properly. Steel alloy is about 10 times stronger than aluminum! We accept aluminum inserts available for the 5553 kit for certain racing applications. But for normal applications steel is better.

The Time-Sert 5600 has the largest outside diameter insert available (almost 3/4″) which can be used when a previous repair has fabricated the hole besides large for other kits. The Fourth dimension Sert 5600 besides works for more applications than the Calvan 38900 does. We have the "How to" video (beneath) that demonstrates how to use the largest kit available (Fourth dimension Sert 5600) to finally fix the dreaded "repeat" blown out spark plug that has left the hole too big to fix for regular kits.

Nosotros've sold thousands of these spark plug thread repair kits, saving Ford owners a lot of time – and money in the process. We'll explain why this should be the side by side and last "over the fender" repair (fifty-fifty in vans) purchased for this item application. Again we tin can assistance with choosing the correct kit, but beneath is a basic guideline for Ford four.6, 5.iv & 6.8 engines that employ M14x1.25 spark plugs. Also a video I did on an F150 using the Time Sert 5600 kit.

Time Sert 5553 – Repairs spark plug holes smaller than .663″ (16.8mm).

The exterior diameter of the insert is .69″- it'southward Double Over-sized, used on many applications and has a Triton counter-diameter needed for some 2001 and up. *Note Add-On Kit 5588 for repairing holes larger than .663″ (xvi.8mm) repairing holes up to .73″. Works for SOHC and DOHC engines. The original size plug M14x1.25 is used. This kit is Made in the USA.

Time Sert 5600 – Stand up Alone Kit that repairs spark plug holes larger than .663″ (16.8mm).

Uses one insert within another one. The exterior bore of the largest insert is .77″ – it'south Triple Oversized. Used on many applications and has a Triton counter-bore needed for some 2001 and upwardly.*Note Add-On Kit for installing the Double Over-sized inserts for holes smaller than .663″ (sixteen.8mm) is kit number – 5588. Works for SOHC and DOHC engines. The original size plug M14x1.25 is used. This kit is Made in the USA.

Calvan 38900 – Repairs spark plug holes up to approximately .678″ (17.24mm).

.678″ is the reamer O.D. size. The outside diameter of the insert is .73″. Nosotros also have this kit available with one insert which is priced lower – CAL38900-one. Due to the guide being required this kit has a limited application (compared to Fourth dimension Sert ). Fits only Ford SOHC 4.6, 5.iv and six.8 engines from around 1996 to 2000. Since there'due south no counter-bore for certain engines from 2001 and upwards for this brand, we recommend the Time Sert kits listed above for those applications. The 38900 works for only certain SOHC engines. The original size plug M14x1.25 is used. This kit is made with Globally Sourced Components.

Make	Model	Engine iv.half-dozen	*Year Exercise Caution**
Ford	Crown Victoria	4.6 SOHC 2V
Mercury	K Marquis	4.vi SOHC 2V
Ford	Mustang	4.six SOHC 2V	1996 – 2004 Excludes Cobra
Ford	Thunderbird	4.6 SOHC 2V
Ford	E150	4.half-dozen SOHC 2V
Ford	E250	4.half-dozen SOHC 2V
Ford	Expedition	4.6 SOHC 2V
Ford	Explorer	4.6 SOHC 2V
Ford	F150	4.six SOHC 2V
Ford	F150	iv.half dozen VIN W Simply	2009 *38900 for 2V'southward merely
Ford	F150	4.half dozen 3 Valve	2009 *Come across 39300 Kit
Ford	F250	4.6 SOHC 2V
Lincoln	Town Machine	iv.6 SOHC 2V
Mercury	Cougar XR7	4.six SOHC 2V
Mercury	Backwoodsman	4.6 SOHC 2V
Brand	Model	Engine 5.4	*Year Caution**
Ford	E150/E-Series	five.4 SOHC 2V
Ford	F150	v.four SOHC 2V
Ford	F150	5.four SOHC 2V	2004 *38900 for 2V's only
Ford	F150	5.4 SOHC 3V	2004 * if 3V See 39300
Ford	F250 & F350	5.iv SOHC 2V
Ford	Expedition	5.four SOHC 2V
Ford	Excursion	five.4 SOHC 2V
Lincoln	Navigator	5.four SOHC 2V	1998-1999 *38900 2V's only
Lincoln	Navigator	five.4 DOHC 4V	1998-1999 *if 4V Encounter 5553
Make	Model	Engine vi.viii	Year
Ford	Excursion	6.8 SOHC 2V
Ford	F250-550, F53	6.8 SOHC 2V
Ford	Motorhome	6.eight SOHC 2V
Ford	E350- E450	half-dozen.8 SOHC 2V

Ford 3V Engines

Note that 2004 and upward 3V engines apply a dissimilar spark plug thread repair kit – Calvan 39300 or Fourth dimension-Sert 3221. The Calvan 38900 is for 2V, SOHC engines from effectually 1996-2016, if working on a DOHC InTech engine, use Fourth dimension-Sert 5553 or 5600. If working on an 01 or up SOHC with M14x1.25 plugs the Time Sert 5553 or 5600 is our tiptop choice. If working on a 2004-08 3V engine with M16x1.v spark plugs use the Calvan 39300 or the Fourth dimension-SERT 3221. If working on a 2008 and upwards 3V engine with M12x1.25 use the 4212H.

More on Ford Spark Plug Blow Outs – What causes information technology?

Ford spark plugs blowing out is a common problem with engines in Ford F150 option up trucks, Mustangs, Crown Victorias, Vans, Expeditions and motor homes. A video showing spark plug thread repair using the Calvan spark plug thread repair kit being used can be viewed on the Calvan 38900 clarification page. Read on for more information.

Ford four.6, 5.iv and 6.viii modular engines are prone to spark plugs being diddled out of the cylinders due to the aluminum threads failing. If the spark plugs are not tight plenty the spark plug vibrates until the aluminum is weakened to a point the spark plug shoots out. Some blame faulty aluminum, merely there are no other issues with any other part of the heads. Ford originally had a lower torque specification and later on revised it making the torque spec higher and plugs tighter. When the threads are near to come loose at that place is often a slight ticking sound/noise, like a small "exhaust manifold leak" would sound. Equally stated before, the problem usually starts if the spark plug is loose. The coil keeps the plug from bankroll out completely. The spark plug vibrates until the aluminum threads in the cylinder head are deteriorated to a bespeak that the spark plug ejects from the pressure of the compression from the cylinder. The spark plug ejecting typically breaks the coil on the way out.

Although rare, it'south possible an engine compartment burn down can outset due to the raw fuel escaping the engine cylinder and the broken coil can provide the spark. We have many Ford dealers that apply Fourth dimension Sert and Calvan, however there are some Ford dealers that volition not recommend repairing the threads. Many only recommend replacing the cylinder head. Because of the cost of labor and parts involved in replacing the heads, we recommend using the appropriate thread repair kit made by Fourth dimension Sert or Calvan. After the repair the threads will exist stronger than original.

Below is another reason nosotros recommend using the over the fender repair equally opposed to removing the heads.

Gaining access to the cylinder head bolts and removing the heads is difficult on trucks and SUV'south. To remove and re-torque the heads, nigh Ford technicians do a "cab off" or "body off" operation. On trucks the cab is unbolted from the frame; on SUV's and vans the entire torso is unbolted from the frame, the electrical wiring, AC lines, radiator hoses, heater hoses, master cylinder, etc. are asunder. This allows the tech to use the vehicle elevator to raise the cab or body off of the frame. In one case this is done the engine tin can be serviced much easier. This procedure takes less fourth dimension than you might expect after the tech has done a few of these and knows exactly what needs to be done. Notwithstanding, using one of our kits and eliminating the need to do all that extra work is obviously the most cost effective method.

Below explains the difference between HeliCoil and the Fourth dimension Sert and Calvan blazon insert.

Many techs at repair shops will use a Heli-coil repair kit to install a new Heli-ringlet insert. Techs are familiar with HeliCoils that are good for many applications. Many times, the proper noun HeliCoil is used as a generic name for a thread insert. This is similar to how some people say "Kleenex" but they are really using the discussion every bit a generic term for facial tissue. Simply to clarify though; The Fourth dimension Sert and Calvan type inserts are Not the aforementioned every bit the Heli Coil. The Time Sert and the Calvan inserts are much thicker and much stronger and will not leak compression. They too last the life of the vehicle. That beingness said, I actually have used the Heli-coil (wire coil) repair kit on 2 dissimilar occasions (years before I started selling tools) and neither of them failed that I am enlightened of. Sometimes they neglect when the spark plug is removed on the adjacent plug change. One concern of using the Heli-curl is that combustion pressure may escape the cylinder since the spark plug may not seat perfectly. I am likewise aware of a very experienced tech (also an ASE Master Tech) I used to piece of work with, that installed a Heli-coil. However it did neglect inside a calendar week after it's installation. The cylinder head was removed and sent to the automobile shop, later on information technology was deemed as "not repairable" by the car shop. If we would have but known about the Time Sert and Calvan repair kits back then, the cylinder head could have been saved. This is considering the Time Sert and Calvan inserts are much thicker and are large enough to repair a spark plug hole that has had a Helicoil neglect previously. In fact, we commonly sell to customers that have had a Heli-Coil or Sav-A-Thread repair neglect and blow back out. We also have had many customers that take tried inexpensive parts store kits that only bought them a niggling time, before they were back in the same situation, with a Blown spark plug.

DenLorsTools.com and WiseAutoTools.com has sold many Time Sert and Calvan kits over the years. The kit numbers listed on this page have had no reported failures! 1 of the all-time features is that the spark plug thread repair inserts can be installed over the fender without the need to remove the cylinder caput.

Using the Fourth dimension Sert or the Calvan Kits
These kits have much thicker inserts that can exist used when other thinner repairs like the Heli-scroll or Sav-A-Thread accept failed to concord. Using these kits crave virtually the same access as if y'all were changing the spark plugs. Just a few steps more than. The pedagogy videos that we provide, layout details on using the kits. Upon request when purchasing from us, we provide a compilation of the tips we think are important when using these kits. These tips are emailed to our customers upon purchase. We will besides personally answer questions if needed, but we've institute the tips clarify the job.

At checkout only write "Tips" in the Comments field and we volition email the tips when processing the club.

Additional Tips

Emailed free later purchase.

Time Sert products are proudly made in the Us – Reno Nevada. Horizon Tools (Due north Carolina) provides us with the Calvan Kit, also sold as Mount9200 and other labels including Blue Point (sold by Snap On for virtually twice the price). Many of our customers with 4.6 or 5.4 or vi.eight engines, decide to put inserts in all cylinders. Some but set up the failed ones and cheque the tightness on the others. Either way, this helps prevent the possibility of any hereafter spark plug blow-outs.

Basic Tool List
1. Standard Pliers (not included) 5/8″ Spark Plug Socket (non included)
2. 3/8″ Bulldoze Extensions (not included)
three. Inspection Scope/Photographic camera (not included) – Utilize to check for metal in cylinder.
4. Air Ratchet (not included) If a good quality air ratchet is not on manus we can ship one at the same time.
five. Starter Push-optional (not included) Manually turning the engine with a socket and ratchet on the crank bolt eliminates the need for a starter push.
6. Cylinder Leak Detector (included in 38900 kit) Bachelor separately.
7. Air Accident Gun with viii-12″ of Small Tubing (not included)
eight. Safety Spectacles (not included)
nine. Lubrication like PB Blaster or WD40 (non included)
10. JB Weld (not included) Loctite is included in the Time Sert kits
11. 3/8″ Ratchet (not included)
12. Store Towels (not included)
13. Air Compressor (not included)
14. Brake Cleaner, to assistance clean out the cylinders and provide make clean threads for loctite or JB Weld to adhere to.

Below are a few of the questions we've answered over the years nigh Ford Spark Plug Blowouts.

Question: I take a 1999 Ford F150 with a 4.6 liter Triton engine with 126,000 miles on it. The number three spark plug blew out of the cylinder caput. I chosen my local repair shop and was told that this was a common problem with this design engine because of the extremely thin (aluminum) casting in the spark plug area of the engine caput, at that place is only about five threads for a spark plug. How are your inserts improve?

Answer: While it is true there are but five threads for the spark plug in this design engine for the spark plug and the Calvan insert has five spark plug threads also, the Calvan spark plug insert is steel not aluminum and the insert itself is held in place with ten external threads. The Calvan spark plug insert improves the design and immovability at fraction of the cost of replacing the cylinder heads with the same design weakness. Fourth dimension Sert offers fully threaded inserts PN 51457.

Question: I am selling my truck as fast as I tin get a spark plug to stay in long enough to get rid of it. I wanted to use a Heli-coil because I won't have to drill, only the thread tool isn't long plenty to reach in the spark plug recess, whatsoever suggestions?

Answer: I personally recommend the Time Sert or the Calvan tools because they are a better repair, but if yous would rather employ the thinner Heli-coil insert, the HEL5396-14 has the longer thread tool than the standard Heli-coil kit.

Question: I take Ford van that has had a Sav-A-Thread installed previously, information technology has blown out and I want to know if the Calvan insert will work since the Sav-A-Thread has left a bigger hole at present?

Answer: Yes, the Calvan spark plug repair insert is a larger insert and has worked well for our customers earlier, saving the expense of replacing the heads. The Fourth dimension Sert 5600 has the largest outside diameter and therefore can relieve heads that take pretty big holes. In fact up to .73″.

Question: I bought a rebuilt head and come to discover out 1 spark plug holes had a repair insert, it blew out final week. The cylinder head has a warranty, but I cannot afford the down time all over again. Volition the Time Sert or Calvan insert repair this hole?

Respond: Yeah, the Time Sert or the Calvan inserts, both have thicker beefier repair inserts that you don't have to worry nigh. And I e'er tell our customers that when purchasing a rebuilt head of this type to be aware of the possibility that inferior repair inserts may already exist in the head. Buying a brand new head would insure that there are no cheap inserts, but you would be stuck with the original weak design. Either the Time Sert or the Calvan thread inserts volition salvage down fourth dimension, money and are stronger due to the material being steel blend instead of aluminum similar the original threads.

Question: Why are these kits so expensive? I can purchase a $20 kit at the parts store.

Answer: The short answer is you go what yous pay for. The kits we sell are considered a permanent blazon repair as opposed to the parts store kits which are temporary at best. Our kits likewise take longer tooling to fit downward into spark plug wells. Our kits don't required striking the insert with a hammer. Our kits either have a guide or take piloted tooling to proceed the repair insert straight. Our inserts cannot be screwed also far. Parts shop inserts have no "stop" which allow them to exist screwed all the way downwardly in the engine if the installer is not careful. Nosotros commonly go calls from customers subsequently they take used a parts shop insert and have dropped information technology into the cylinder or the insert has blown back out making the hole bigger, requiring an oversize repair; or in the instance of the Dorman, they have been breaking in half recently. This required removal before any of our kits can be used.

For even more information, run into our main page with many more articles and videos on how to repair stripped threads.

We've been selling specialty tools and aluminum thread repair kits since 2005. Call for help in finding the best spark plug thread repair kit for your situation at 800-524-9783 or 800-734-8665 x251 or provide your details past using our Contact Form.