Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
0517311/14/20050522610018741Malfunction indicator lamp on with diagnostic trouble code p1131 and/or p1151 - 4.2l engine. *tt01/12/2006
04160111/14/20050522810018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt01/12/2006
ENGINE AND ENGINE COOLING - ENGINE
0721210/01/200710023943Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe02/20/2008
ENGINE AND ENGINE COOLING - ENGINE - OTHER FUEL TYPES - TURBO-CHARGER
2022804/01/2008100248651999-2008 7.3l/6.0l/6.4l/4.5l diesel f-super duty - clean the charge air cooler (cac) system after certain turbo or engine failures - service tip. *nj06/03/2008
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
CSP-08B0105/16/200810026389Ford: certain 1999-2001 model year vehicles up to 6000 lb gvwr registered in new york and certain 2001 vehicles up to 6000 lb gvwr registered in the state of maine, certified for sale in california-federal emission warranty refund. *pe10/23/2008

Consumer Complaints


Fail datemilesoccurencesPurchase date
ENGINE
06/26/2012112000
 As i was leaving a stop sign, i accelerated and a spark plug blew out of it's hole and will not go back in. this is a product defect that can cause serious injury or deaths to unknowing ford owners. ford should recall asap.
05/07/2012
 The truck started on fire while sitting in the driveway hours after being parked. by the time we realized it was on fire, it was totally out of control and the truck well beyond saving. it burned so hot it melted the tires, the siding of the house and destroyed part of a privacy fence. we kept water on the fire until it went out about an hour and a half later. the fire started under the hood and the whole front of the truck is almost unrecognizable. the owner ( kevin fjerstad ) is an auto mechanic and has been for forty plus years. we run an auto repair business. we had heard vague things about fords and fires but did not look into it until after the incident. we purchased the truck this winter and never got any recall notices for the cruise control switch problem. the prior owner says he did not either. we have not yet contacted ford because of reading all the horror stories of how they refuse responsibility. we had liability insurance only. the anger is letting up a bit and the shock has worn off and now we are figuring out the next step. reporting the incident to you seems to be it. i will contact ford on monday.
ENGINE AND ENGINE COOLING
04/13/2012202000
 Pulled out of side road onto major highway and suddenly a loud flapping noise from engine was heard. immediately pulled to shoulder of road and turn vehicle off and called for assistance. was told that a spark plug was the cause of the problem and that it should be a easy fix, this was not the case because the head had to be removed to extracted to damaged plug. our fix is costing upwards of $700.
01/31/201268000
 Tl- the contact owns a 2001 ford f-150 triton. the vehicle was taken for state inspection when the contact was advised that the engine, engine manifold and bolts were corroded. the vehicle was taken to the dealer where the failure was confirmed. the manufacturer was not contacted. the vehicle was not repaired. the failure mileage was 68,000 and the current mileage was 71,000. kmj
01/31/201268000
 Tl- the contact owns a 2001 ford f-150 triton. the contact stated while the vehicle was inspected by the state they confirmed corrosion of the engine manifold and bolts. the vehicle was taken to the dealer. the confirmed the engine and manifold were corroded. the manufacturer was not contacted. the vehicle was not repaired. the failure mileage was 68,000 and the current mileage was 71,000. rds
03/18/201228000
 Tl* the contact owns a 2001 ford f-150. while parked, the contact noticed smoke coming from under the hood. after opening the hood the contact noticed that the manifold and the wiring harness was on fire. the contact stated that the vehicle had been shut off and had not been driven prior to the fire. the contact was able to extinguish the fire with a fire extinguisher. the vehicle was not taken to the dealer for diagnostics or repairs. the approximate failure mileage was 28,000.
03/18/201228000
 Tl-the contact owns a 2001 ford f-150. while parked, the contact noticed smoke coming from under the hood. after opening the hood the contact noticed that the manifold and the wiring harness was on fire. the contact stated that the vehicle had been shut off and had not been driven prior to the fire. the contact was able to extinguish the fire with a fire extinguisher. the vehicle was not taken to the dealer for diagnostics or repairs. the approximate failure mileage was 28,000. kmj
03/18/201228000
 Tl-the contact owns a 2001 ford f-150. while parked the contact noticed smoke from underneath the hood. after opening the hood the contact noticed the manifold and the wiring harness was on fire. the contact stated the vehicle was not off and had not been driven prior to the fire. the contact was able to put the fire our with a fire extinguisher. the vehicle was not taken to the dealer for diagnostic. the vehicle was not repaired. the approximate failure mileage was 28,000. ds
12/23/2011122989
 Spark plug blow out caused excessive damage to engine. engine had to be replaced at a cost of $6200.00. this is a known problem for 1999 to 2005 engines.
10/09/2011143000
 I was driving to work and heard a loud pop and stopped the truck and called the tow truck. the mechanic informed me that a spark plug blew out of the head of the engine and it was going to cost $550.00 to fix, he also said that it would be a temporary fix and that i would need a new engine because of the damage. i did some research and found that this has been a problem for some time with these engines because of the aluminum heads and there were only 3-4 threads actually holding the spark plug. a ford motor co. warranty inspector says the ford triton v-8 engines are dropping like flies because of blown spark plugs. i would like to address the ford spark plug blowout issue. ford triton engines from 1997 to 2003 had a problem where spark plugs would randomly fly out the cylinder head. this appears to be due to a few issues (engineering design flaw), first there are insufficient threads (3-4) in the head to properly hold the spark plug. second the threads in the head are not inserted, in other words the threads are in the aluminum and are not very strong. spark plug ejection is dangerous because fuel vapor starts coming out the spark plug hole, which is clearly a serious safety issue. the fuel vapor can be ignited by the loose spark plug - and in fact there have been a small number of cases reported of engine fires due to spark plug ejection/blowout. ford needs to be held responsible for the repairs of spark plug blow out and should extend the warranty regardless of age on the spark plug blow out issue, they also should be forced to pay a fair amount of labor time, because most of the repairs cost thousands of dollars. ford has been aware of this serious issue of an engineering-design flaw and needs to recall 17 million vehicles from 1997-2003.
10/03/2011249000
 Tl* the contact owned a 2001 ford f-150. the contact stated that the vehicle was parked for a few days when it suddenly caught on fire and burned to the ground. the contact suffered minor burn injuries as a result. the vehicle was not taken to have the failure diagnosed or repaired. the vehicle was destroyed. the manufacturer was not made aware of the failure. the failure and current mileages were 249,000.
10/09/2011143000
 I was driving to work and heard a loud pop and stopped the truck and called the tow truck. the mechanic informed me that a spark plug blew out of the head of the engine and it was going to cost $550.00 to fix, he also said that it would be a temporary fix and that i would need a new engine because of the damage. i did some research and found that this has been a problem for some time with these engines because of the aluminum heads and there were only 3-4 threads actually holding the spark plug. a ford motor co. warranty inspector says the ford triton v-8 engines are dropping like flies because of blown spark plugs. i would like to address the ford spark plug blowout issue. ford triton engines from 1997 to 2003 had a problem where spark plugs would randomly fly out the cylinder head. this appears to be due to a few issues (engineering design flaw), first there are insufficient threads (3-4) in the head to properly hold the spark plug. second the threads in the head are not inserted, in other words the threads are in the aluminum and are not very strong. spark plug ejection is dangerous because fuel vapor starts coming out the spark plug hole, which is clearly a serious safety issue. the fuel vapor can be ignited by the loose spark plug - and in fact there have been a small number of cases reported of engine fires due to spark plug ejection/blowout. ford needs to be held responsible for the repairs of spark plug blow out and should extend the warranty regardless of age on the spark plug blow out issue, they also should be forced to pay a fair amount of labor time, because most of the repairs cost thousands of dollars. ford has been aware of this serious issue of an engineering-design flaw and needs to recall 17 million vehicles from 1997-2003.
10/03/2011249000
 Tl* the contact owned a 2001 ford f-150. the contact stated that the vehicle was parked for a few days when it suddenly caught on fire and burned to the ground. the contact suffered minor burn injuries as a result. the vehicle was not taken to have the failure diagnosed or repaired. the vehicle was destroyed. the manufacturer was not made aware of the failure. the failure and current mileages were 249,000.
10/03/2011249000
 Tl- the contact owned a 2001 ford f-150. the contact stated that the vehicle was parked for a few days when it suddenly caught on fire and burned to the ground. the contact suffered minor burn injuries as a result. the vehicle was not taken to have the failure diagnosed or repaired. the vehicle was destroyed. the manufacturer was not made aware of the failure. the failure and current mileages were 249,000. kmj
10/03/2011249000
 Tl-the contact owned a 2001 ford f-150. the contact stated that the vehicle was parked for a few days when it suddenly caught on fire and burned down. the contact suffered minor burn injuries as a result. the vehicle was not taken to have the failure diagnosed or repaired. the vehicle was destroyed. the manufacturer was not made aware of the failure. the failure and current mileages were 249,000. sm.
09/08/201098000
 Tl* the contact owns 2001 ford f-150. the contact stated that the vehicle exhibited an abnormally loud knocking noise from the front end of the vehicle. the contact inspected under the hood and noticed that the spark plug located nearest to the driver side had disengaged from the helium coil head without warning. the vehicle was towed to an authorized dealer where a helium coil kit was installed. a few months later, the same failure recurred and the engine was replaced by the dealer. the manufacturer was made aware of the defect. the approximate failure mileage was 98,000.
09/08/201098000
 Tl-the contact owns 2001 ford f-150. the contact stated that the vehicle exhibited an abnormally loud knocking noise from the front end of the vehicle. the contact inspected under the hood and noticed that the spark plug located nearest to the driver side had disengaged from the helium coil head without warning. the vehicle was towed to an authorized dealer where a helium coil kit was installed. a few months later, the same failure recurred and the engine was replaced by the dealer. the manufacturer was made aware of the defect. the approximate failure mileage was 98,000. kmj
09/08/201098000
 Tl-the contact owns 2001 ford f150. the contact started the ignition and there was a loud knocking noise coming from the front end of the vehicle. the contact inspected underneath the hood and noticed the spark plug located nearest to the driver's side disengaged without warning from the helium coil head. the vehicle was towed to an authorized dealer where a heli coil kit was installed. a few months later, the similar failure recurred and the engine was replaced by the dealer. the manufacturer was made aware of the defect. the approximate failure mileage was 98,000. js
04/08/2011209000
 Tl*the contact owns a 2001 ford f-150. the vehicle was parked and shut off when a fire began on the driver's side of the hood. the fire department extinguished the fire. a police report was not filed and there were no injuries. the vehicle was not moved from the location and was not repaired. the failure and current mileages were 209,000.
04/08/2011209000
 Tl-the contact owns a 2001 ford f-150. the vehicle was parked and shut off when a fire began on the driver's side of the hood. the fire department appeared on the scene to extinguish the fire. a police report was not filed and there were no injuries. the vehicle was not moved from the location and was not repaired. the failure and current mileages were 209,000. sm.
03/07/2011106000
 Started truck heard a loud pop engine running rough checked,spark plug blew out destroying coil pack now called ford dealer they said no recall checked on internet noticed a lot of people same problem. a lot money to repair. i had just got back from a 600 mile trip if this had happened during trip would have cost me up to $4.000 to get on road again, this should be a recall! and if i get it fixed i will have to get rid of it because people are complaining 2 or more plugs are blowing out and i can not afford the fix .
09/30/2010135000
 Tl- the contact owns a 2001 ford f150. the contact stated the vehicle burnt at his work parking lot. the vehicle wasn't occupied and the vehicle that was parked to the contact passenger side also burnt. the fire department was present. the manufacturer was contacted they advised to send photos and supporting document, but they have not taken the responsibility for the failure. the failure and the current mileage were 135,000. li
09/10/2009113000
 Tl- the contact owns a 2001 ford f150 with a titan engine. the contact stated that the vehicle has blown out 4 spark plugs and blew them into the coil pack. the contact states that this failure causes the vehicle to stall out in traffic. ford motor company was contacted and they stated that the owner file a safety complaint. the vehicle has not been repaired. the vehicle currently has approximately 113,000 miles. rd
04/24/2010
 2001 ford f-150 with a 4.6 triton-2 spark plugs blew out of the head on the driver's side. had them repaired and they blew out again a month later.
04/20/200940000
 Tl*the contact owns a 2001 ford f150. the contact stated when starting the vehicle the engine would exhibit a continuous increase and decrease in engine rpms. while driving at speeds of at least 20 mph, the engine would idle tremendously loud and the check engine light illuminated on the instrument panel. the vehicle was taken to a local mechanic he performed an oil change. the failure persisted and the vehicle was taken to a second mechanic. the mechanic replaced the mass sensor however; the repair did not correct the failure. the mechanic then advised cylinder three had misfired. the failure had not yet been corrected to date. the failure mileage was 40,000 and the current mileage was 62,052.
03/03/20101400001
 Ford f150 spark plug # 8 blow out while driving to work. there were noxious fumes that eventually become very strong. i have read numerous complaints about this and feel that this must be a safety hazard due to obvious raw fuel, heat and potential sparks. *tr
01/16/201098000
 Tl*the contact owns a 2001 ford f-150. while driving 40 mph the contact heard a banging noise in the engine and the vehicle started to lose power. the contact was able to safely drive onto the emergency lane and after looking under the hood, he observed that a spark plug was missing. the vehicle was towed to a local mechanic to have the vehicle repaired. the contact is concerned that a crash could have occurred when the spark plugged popped out of the engine. the vin was not available. the failure mileage was 98,000.
11/01/2006800001
 I had an original spark plug blow out of my ford f-150 v-8 triton motor while i was driving on the freeway. it made a loud pop noise and then i seen a flame i pulled over right away and shut off the truck and called for help. thankfully i was not hurt and the fire went out and did not burn the truck to the ground. ford refused to fix it they said it was not a lubricated part and my warranty didn't cover the $2000-3000.00 repair. it is a defective design and they know it but are not allowed to fix it under the warranty's. *tr
12/03/20091080001
 Spark plug blew out of 2001 ford f150. *tr
11/04/2009980001
 2001 ford f-150 the engine on the truck caught on fire came to work at 6am around 10:15am fire department was call truck was on fire, the radiator and front end was all melted engine completely burn there was a hole in the middle of the dash board and all the wires look burn. *tr
08/22/2009240001
 My 4.6l engine on my 2001 ford f150 pickup truck needed new spark plugs. i have changed plugs on many motors before so it is not new to me. i read the service manual and learned more about this particular model by reading information off the net. i was very careful and did everything the service manual and net info told me to do. even so, the very first plug i removed from the engine block broke. the porcelain and hex nut came out in one piece but the bottom threads and ground electrode remained in the engine block. i went back to the net to search for solutions to the problem only to find that more often than not the spark plugs on these models will break apart when removing them. i believe this falls under the category of a recall. this will be a costly repair that i cannot do myself and i don't believe ford can justify this many plugs breaking. *tr
07/14/200911
 I own a 2001 ford f150 pickup. i've had to change a coil (above spark plug) on this truck several times (at least 5 failures) since i've owned this truck. when a coil goes out the truck misses a lot and at times when you slow down to turn a corner the truck will die, causing me to brake to an immediate stop because the power stearing goes out. very dangerous. *tr
04/11/20091350001
 Spark plug blown out of engine. 2 years after dealer installed. *tr
04/27/20091490571
 I have a 2001 ford f150 with the 4.6l triton. driving home from work on the evening of april 27th, im at a red light. as soon as it turns green i push the pedal to go. out comes the spark plug from the block. i have read numerous complaints about this issue on the internet. i cannot believe ford has not issued a recall over this. not only is it dangerous, but its a silly problem to have. i have had 5 estimates to fix this problem all over $2000. there's no way i can afford this, i am looking for a class action lawsuit to join. very disappointed in ford and when i get this fixed i will never own another ford vehicle. *tr
04/10/20091245151
 One morning upon starting my 2001 ford f-150, i heard a loud pop and knocking coming from my engine compartment. the #3 spark plug on the passenger side, shot out of the cylinder head and broke the #3 cylinder ignition coil, stripping the threading on the cylinder head. ignition coil, spark plug, and steel insert threading were replaced. mileage = 124515 5.4 v8 this is appears to be a well-known problem: http://abclocal.go.com/kgo/story?section=news/7_on_your_side&id=4757786 http://www.consumeraffairs.com/news04/2007/03/ford_spark_plug_fire.html http://ezinearticles.com/?ford-spark-plug-problems---spark-plugs-broken-and-blowing-out&id=1107803. *tr
03/11/2009730001
 Fire f 150. *tr
03/11/20091970001
 Tl*the contact owns a 2001 ford f-150. the vehicle caught fire while parked outside the contact's place of work. the fire department was notified, but did not state what caused the fire. the fire burned the motor, created a hole through the hood of the vehicle, and scorched the entire dashboard. the windshield glass burst into pieces and the vehicle was towed to his residence. the ford dealer filed a case and followed-up with the contact within 15 business days and informed him that someone would diagnose the vehicle. the contact was also informed that there was a recall for the cruise control. the vin and nhtsa campaign id number were unknown. the failure and current mileages were 197,000. updated 04/17/09. *lj updated 04/20/09.*jb
02/17/20091
 2001 ford f-150 blew out a spark plug for the 2nd time. caused the truck to go off the road since it immediately lost power while going 65mph. this is the 2nd one that has blown and will likely cost a few thousand dollars to fix. there is a forum on consumer affairs with hundreds of people with the same exact problem with their ford vehicle. the website link is http://www.consumeraffairs.com/automotive/ford_spark.html if you would like to check it out. *tr
02/07/2009900001
 Driving 35 to 40 miles an hour. heard a loud pop under the hood pulled over and found a spark plug had blown out of the engine. not fixed yet. *tr
01/08/20091445601
 I own a 2001 ford f 150 w/ the 5.4 triton engine, while i was backing the truck out of a restaurant, the engine made a loud pop. i took the truck to a ford dealership...they told me that the engine blew the # 3 spark plug out. the service department told me that this is a common problem with the motor because of bad designed heads. they advised me that i would be better off with a new engine at the cost of $4800.00. i pulled up a site on the internet that states that there have been thousands of complaints with the same problems. i feel like ford should have a recall on this engine. *tr
10/05/2008760001
 On 10/5/08, driving near home, slow speed, heard a loud noise from under the hood, lost power. determined that the 4th spark plug on drivers side had unthreaded from engine, damaging coil. on attempt to replace with new spark plug, learned that the cylinder head threads were damaged (stripped). 76,000 miles, spark plug had never been removed, was original from ford factory. *tr
09/30/20081500001
 My 2001 ford f-150 blew a spark plug out of the 7 head on 09/30/2008. the truck has 150k on it. i bought it new in 2001 and have always maintained it. i went out to go to work in the am and the truck just roared when i started it, i found the spark plug on the driveway the threads on the plug were completely in tact. took it ford service and it will cost me $2500.00 to fix with no guarantee. i have found that this is a really common complaint from owners of v8 triton engines. ford needs to do a recall on these vehicles. my brother-in-law is an asi front end mechanic for ford and he says he has seen a lot of this problem. if he didn't live in denver i would have him fix it. my family has always driven ford products. my father was an engineer for ford in detroit. but, i feel that because ford will not stand behind this problem that maybe it is time to switch loyalties. the service department at the dealership displays a so- what attitude. i requested a factory rep to look at the truck and they said either fix it now, or move the truck off their premises. the consumer has no rights anymore. *tr
09/17/2008976731
 Experienced spark plug blowout during regular driving, occurred once in one cylinder of a 2001 ford f150 5.4 triton dual fuel factory propane. used a helicoil kit and repaired the damage and other cylinders to prevent further damage. *tr
09/14/2008108000
 Tl*the contact owns a 2001 ford f-150. after driving 35 mph, the contact parked the vehicle in her driveway. minutes later, the vehicle caught fire under the hood. the fire damaged the neighbor's vehicle and the landlord's fence. the contact later discovered a recall relating to the fire. the detective at the scene believed that the fire was due to the recall. a police report was filed. the manufacturer has not been notified. the nhtsa campaign id number was unknown. the failure mileage was 108,000.
08/17/2008900001
 My 2001 ford f150 blew a spark plug right out of the aluminum head on 8-17-08. vehicle had about 90,000 miles on it. it is a common and repeating failure of the 5.4l v-8 engine and ford will not acknowledge it as a problem. i opted for the helicoil replacement option ($640) over a complete new head ($3000). ford will not pay for any of this even though it is their design flaw. later models have been changed to correct this problem. if it was not a problem then why was it corrected? *tr
07/30/20081400001
 2001 ford f150 with v8 4.6 liter engine blows spark plugs out of the head. had 2 do this in the last 2 months. had to get out of traffic because engine will not run, call tow truck and deliver to repair shop. they redrilled the hole and installed an insert both times. alot of ford engines of this type do this as i now know. afraid to drive this truck and alot of money out of my pocket!!!!!!! *tr
04/26/20081006001
 I have a 2001 ford f 150 w/a triton v8 engine. it blew a plug out and ford knows there is a problem and won't fix the issue. i am have to pay $1,000.00 to repair an engine that is defective right off the factory floor. i have done a lot of research and there is a serious problem and some have caught fire. will people actually have to die before ford is required to do something about it? *tr
04/27/2008157000
 Tl*the contact owns a 2001 ford f-150. after being parked for one hour, the vehicle burst into flames and was destroyed. two vehicles next to the contact's vehicle were damaged. the fire department stated that the fire originated from the engine compartment and a report was filed. the contact has pictures. the failure mileage was 157,000.
08/24/2007127000105/23/2002
 I have a 2001 ford f150 lariat supercrew with the 5.4 liter engine. my family and i were on vacation when the 3rd sparkplug back on the drivers side blew out of the engine and left us stranded. it destroyed the coil in the process and nicked the fuel rail. we had to have a forty mile tow to a mechanic who could put in a helicoil to hold the new sparkplug and also put in a new coil. this cost us $600 including the tow. this was the 2nd ford with a 5.4 liter engine in a week that this mechanic fixed with a blown sparkplug. the nearest ford dealer wanted to replace the entire head at my expense for $3,300 not including a tow. this took place in kalispell montana. since then i have had to check and retighten at least one of my spark plugs every 3,000 miles. the truck had approximately 127,000 miles on it when i blew my sparkplug. *tr
02/12/2008126000107/05/2001
 #3 spark plug drivers side blown out , damaged coil and possibly fuel rail. 5.4 triton engine is in a 2001 f-150 4x4 with 126,000 miles, not very safe with the possibility of a spark right next to the fuel rail. *tr
02/01/200847200109/01/2001
 '99 - '08 ford 5.4l v8's are equipped with 100,000 mile spark plugs from the factory. they are failing in large numbers at well under 50,000 miles. most times pulling the threads out of the aluminum heads of the motor. other times the spark plugs break leaving part of it in the block. my problem was the #7 plug breaking in half while the vehicle was in operation. when i took my '01 f-150 super crew to the dealer i was told that they couldn't replace the rest of the spark plugs because they would probably strip the threads out of the heads when they removed them. *tr
01/20/200814200310/11/2001
 Ford 2001 f150 crew4x4 replaced spark plugs after #4 coil pack went bad then number2 coil pack went bad after only 65,000 miles. then at 142,000miles #6coil pack and sparkplug blew out of motor. *tr
12/20/20071390001
 Drove my ford f150 to work, parked it and 30 - 40 minutes later the entire engine compartment was on fire. i entered the truck 30 minutes after i parked to remove my check book, but i did not see or smell anything that resulted in the fire. the truck was not insured, but appears to be a total loss. *tr
10/20/2007151
 Spark plug blow out. *tr
07/31/200711900102/12/2007
 Tl*the contact owns a 2001 ford f-150. she was informed that her vehicle caught fire. the fire was extinguished using a fire extinguisher and the fire department was called. as of august 3, 2007, the dealer has not repaired the vehicle. the manufacturer stated that they would send a letter to the contact within two weeks. the current and failure mileages were 119,000. updated 02-01-08. *kb updated 02/01/08 *tr
07/26/200730000106/10/2004
 I was driving my 2001 ford svt lightning, with only 30,000 miles on the odometer. no sign of a problem whatsoever. while passing a big truck, pop........and then i lost power and almost didn't complete the pass in time. once i pulled over, i found that a spark plug blew out, and took out a coil on it's way. the ford dealer wants big money for the repair (new heads), and i can't afford it right now. i've found this to be a common problem, and ford won't do anything about it. my plugs are original, so nothing was done by me to contribute to this failure. now my truck is sitting in the driveway, and it can't be driven. hope my other fords don't spit out a plug. *tr
05/29/200783833104/01/2006
 On tuesday morning, 05/29/2007 at 1:30am, i was awakened by a loud boom and a bright flash from outside of my bedroom window. when i jumped up to see what was happening, i saw my truck engulfed in flames. i grabbed my cell phone from beside my bed and dialed 911 as i ran to the front porch. by the time i reached the front porch the entire front of the vehicle was engulfed, the hood was completely gone and the front tires were on fire. when the fire department arrived, the truck was on fire from the front bumper to the rear bumper. the inside of the truck was completely in flames and all of the window glass had either melted or been blown away from the truck body. it was determined by the fire department that the fire began inside of the engine compartment. *tr
02/10/2007930003
 Tl* - the contact owns a 2001 ford f-150. while driving 40 mph the vehicle made a loud popping sound similar to a truck back firing. the mechanic stated the spark plug and coils werecausing the failure. this failure occurred on 2 previous occasions. the recent failure the mechanic was unable to repair by changing the spark plugs, the damagewas more advanced and costly. most ford trucks experienced this failure at 8 years. the vehicle was towed, and was currently at the dealer for repair. the failure and current mileage were 93000.*ak
10/12/2006499103/01/2006
 Dt*: the contact stated while driving 10 mph through a light, and making a left turn under normal road conditions, the contact heard a pop coming from under the hood. after pulling over to inspect under the hood, the contact noticed that the third spark plug had popped out of place from the cylinder head. the vehicle was towed to a dealer who would not inspect the vehicle. it was towed to another dealer via reference from the warranty company. the vehicle was currently being evaluated by the dealer, awaiting the results. the manufacturer was notified and denied that the vehicle was part of the recall list and therefore would not provide further assistance. the contact noticed consumer complaints via website similar to the problems the vehicle had. one similar complaint was odi #10033248.
04/25/200680000204/10/2002
 Spark plug blowout. 2nd. time. *jb
ENGINE AND ENGINE COOLING - COOLING SYSTEM
04/10/20091181461
 While on a trip and 400 miles from home , the vehicle started missing severely. we were able to get to our destination some 180 miles further. the following morning the check engine light came on and the vehicle was malfunctioning badly. we got a dealer to repair it. the intake manifold was cracked and causing water/antifreeze to create the problem. the manifold was replaced along with other necessary parts. apparently this is a common problem on the f-150. *tr
ENGINE AND ENGINE COOLING - ENGINE
06/25/2011151000
 While driving down interstate started to hear a load poping noise from engine. immediately pulled over to find that one of the spark plugs had blown out of the head. had to be towed. still waiting of cost of repairs. researching online, it appears that this is common issue with this motor.
06/17/201180000
 Was driving normally when i started hearing a loud popping noise from engine. took to mechanic and was told the spark plug blew out - was also told this is a common problem with ford triton engines and a design flaw with the engine (too few threads on spark plugs)
06/11/2011170000
 Tl* the contact owns a 2001 ford f150. the contact stated while the vehicle was parked in the driveway, the engine caught on fire. the local fire department was unable to locate the exact origin of the fire. a fire report was not filed. the failure was being investigated by the contact's insurance company. the failure and current mileage was 170,000.
06/11/2011170000
 Tl-the contact owns a 2001 ford f150. the contact stated while the vehicle was parked in the drive way the engine caught on fire. the center hill fire department was unable to locate the exact area were the fire initiated. the insurance company was investigation failure. the failure and the current miles was 170,000. li
05/25/201192356
 I was driving on the freeway when a pop and loud flapping sound was heard. i thought i had blown a tire. the truck lost a good amount of power and was shaking while continuing to make the flapping sound. after taking it in, it turns out it was a blown spark plug that shot out of the engine, damaging the block, plug, and coil. the cost was $630 to fix it.
05/17/201131000
 I have a 2001 ford f-150 lightning with roughly 31,000 miles on it. three weeks back i was turning into my neighborhood at 5 mph, and i head a popping sound, and the truck begins to run roughly. i immediately pull over, and pop the hood, i smell gasoline. i shut the truck off. call a tow truck to my ford dealership. there they tell me that the spark plug has shot out of the cylinder head, stripping the aluminum head. i get the bill for repair in which they re-bore the head, and install a heli coil at a cost of $560 plus labor. the dealership tells me this should in fact strengthen the cylinder, so i continue normal operation of the vehicle tuesday 5/17/11, i was driving on route 290 in worcester when all of a sudden at 70 mph the heli coil pops out causing me instantly lose power. in an effort not to damage the vehicle further i put it in neutral, and coast to the break down lane of a three lane highway and proceed to call aaa to get a tow. once back at the ford dealership the tech tries to do the same thing, and re-bore the head to install another heli coil. he does and takes it for a test drive. the heli coil that he just installed blows. now they are telling me that i need a new cylinder head. a $1600 part, plus 19 hours of installation costing $3600 in total. this as i have been told by the dealership and upon hours of research, is a common problem with the 1999-2003 ford 5.4l triton engine. this is a factory ford defect, they did not drill the appropriate threads for the spark plugs. now it has happened to me twice, this very easily could have gotten me hurt on the highway, or could have set fire to my vehicle since gasoline from the cylinder was spilling onto the hot engine block, directly next to the fuse box, there a current runs through. i have spoken to ford and there is no recall on this. a factory defect, that is costing me almost $4000, through nothing but careful care of the vehicle.
05/09/201068000
 2001 ford f150 supercrew 5.4l. while driving this vehicle the spark plug forcibly came out of the cylinder head. vehicle was not able to be driven after blowout of spark plug. vehicle had to be towed to garage. not sure how or why this happened.
11/12/2010110521
 Spark plugs keep popping out of cylinder head. has happened five times so far. i know of seven other people with the same problem!
03/30/2011127000
 Drove approximately 27 miles, then heard a loud pop under the engine. smelled gas while inside cab with the windows rolled up. loud knocking noise followed. found that the number 3 spark plug had blown out of the head. luckily no fire.
11/15/2010140000
 I have a 2001 ford f-150 with a 4.6 v8 engine and i have now had 2 spark plugs blow out of the passenger cylinder head. the truck has 145,000 miles on it. these did not happen at the same time they were about 12 to 18 months apart. the spark plug had been replaced over a year before the first blow out occured. it also broke both coils on those cylinders. until i started a search to see if anyone else had this issue i was unaware of the danger of fire.
11/16/200171211
 2001 ford f-150 4.2l v6. two spark plugs have loosened and ejected so far.
10/27/201060180
 While driving home from work i heard a loud pop coming from the engine compartment,then sounding like an air compressor. my mechanic told me that one of the spark plugs blew out of the socket and needs a helicoil installed to hold the spark plug. this fix is going to cost about $300. he also stated that this is a common problem in ford truck engines. as of yet there is no recall on this problem!
10/21/2010178000
 I have a 2001 ford f150 crewcab truck. on my way home from work, my vehicle started making an awful noise and the truck instantly started working rough. i pulled over and turned off the truck. my huband came to check on me and when we popped the hood and when i turned on the truck he saw the spark plug coming out of the cylinder. i have yet to have the mechanic look at it. afer reading up on this, i see this is a recurrent problem on ford trucks. i do not understand why nothing has been done regarding this matter. i simply do not have the funds available to pay for this if it is a major repair job nor do i have the means to purchase another vehicle due to the current economic state and were barely getting by as it is. i want something to be done and this issue with ford investigated further. it is a design flaw and this is getting ridiculous. do someone have to die in order for something to be done. thank god i did not pick my kids up yet . thank god i was just starting off from a light and hadn't even got back up to 20 mph. thank god it happens to me and not my husband that drove out to orlando today and was going to use my truck. he would have been severely hurt or worse if this occured at 70+mph. i have read that this could cost in the thousands and when i get an estimate i will update this matter further.something has to be done, there are no more excuses.
08/30/201056000
 Truck with 56,000 original miles. after stopping truck to dispose of trash, spark plug #8 blew out of the engine head while idling. truck immediately towed to ford dealership. dealer stated this is very uncommon problem. helicoiled head. installed new plug. $700.00. when vehicle was picked up from dealership there was a loud knock in engine, but we were told it was within specs and safe to drive. mechanic now says there is a severe rod problem, most likely caused by parts of debris impacting piston and cylinder head. estimated cost $4,500. for rebuilt engine.
09/15/2010136000
 Spark plug blown out of engine
09/18/2010101085
 Driving at 55mph on state highway,3rd spark plug back on passenger side of 2001 ford f-150 4dr. 5.4l. blew out of head, broke coil pack and fell onto highway. had truck towed to house and it still sits. i cant afford a repair of $2000+
09/15/2010136000
 Spark plug blown out of engine
09/18/2010101085
 Driving at 55mph on state highway,3rd spark plug back on passenger side of 2001 ford f-150 4dr. 5.4l. blew out of head, broke coil pack and fell onto highway. had truck towed to house and it still sits. i cant afford a repair of $2000+
08/20/2010111000
 Problem was instant while driving north on rt. 18. ford f150 v8 started missing, smelling of gas, making loud noise which appeared to be every time the belt went around, unable to excellerate, had to keep one foot on gas and one foot on brake at red light. problem was that the sparke plug overheated and ejected. safety issue with fuel vapors coming out of spark plug hole and could ignite from loose spark plug. ford denies this is a problem and claim there has only been three reported cases when i had the dealer call them. after talking about it at work, i found another employee that had the same problem. so there are two cases right there that they didn't even know about. how many cases do they really know about or deny knowing about?
06/10/2010147000
 Spark plug #3 has blown out of cylinder head on two occasions. this second occurrance damaged the threads requiring repair with a helicoil kit. this defective head can cause fire hazard
05/15/2010202000
 2001 ford f150 5.4l cracked intake manifold. cranked truck and saw antifreeze leaking from passenger side of intake. getting motor fixed and have verified it to be cracked manifold.
03/24/201085000
 I own a 2001 ford f150 with a 5-4 triton motor.had a spark plug blowout while on the freeway,it occured on number 3 cylinder and 2 more that were loose on the engine.mechanic repaired by installing an insert do to stripped out threads.also when the plug blew out it damaged the coil pack.i saved the parts that were replaced.
10/22/200056000
 Tl*the contact owns a 2001 ford f150 lightning sbt. the contact stated that the spark plugs are blown from the engine. while driving 45 mph the sparks plug blew out while the engine was running. the vehicle was towed to a repair shop where they replaced the spark plugs. the manufacturer was called and informed him to call nhtsa to file a complaint. the failure mileage was 56,000.
02/05/20101945033
 I have a 2001 ford f-150 with 195,000 miles on it ,.. i am the third owner and have not had any problems with it until now.. i was driving down the road and suddenly heard a loud disturbing sound coming from the engine compartment,.. i pulled over and shut the truck off immediately,.. i opened the hood and did not see anything wrong, so i started it back up and the same noise could be heard,.. i looked under the hood and could see a spark by where a spark plug would be,.. i shut the truck off and investigated a little bit,.. i noticed that the coil was off and the spark plug was laying by the valve cover,... i had to call my brother to haul the truck home since i knew that driving it like that could cause engine problems,.. after doing a little research about this problem, i found that spark plugs popping out of their holes is kind of a common thing for ford triton engines. why has this issue not been addressed by ford motor company yet,... i have been told that they have known about tit for quit some time and haven't been forced to fix the problem so they probably wont send out a recall for this... what can b e done to fix this problem !!! *tr
11/28/20091390001
 The #3 cylinder spark plug blew out on my 2001 ford f-150 lariat. my truck has the 5.4 liter engine and it has 139,000 miles. i was driving approximately 15 mph and the spark plug blew out. there was a loud popping noise from the engine compartment. upon investigation i found the #3 cylinder spark plug had blown out and also destroyed the coil on top of the spark plug. *tr
11/17/20093
 Blown spark plug from 2001 f-150 (lightning) note: this is the third blown spark plug. the first time ford replaced the entire head (under warranty). the next two were out of my pocket (at $1k each). *tr
01/08/20091500001
 My wife and i were driving to florida from north carolina. i have a 2001 ford f150 5.4 triton. a loud pop, and the spark plug blew out of the head, taking the coil with it. very expensive repair. this is a widely reported problem with this model and is an obvious manufacturer defect due to insufficient thread depth in the head. *tr
08/28/20091510001
 I have a 2001 ford f-150 xlt 4.6l with 151,000 miles. a few days ago, i was driving on interstate 64 and heard a loud pop from the engine area. the engine started to miss violently. i pulled to the side of the road, raised the hood and noticed the spark plug had blown out. of course, i could not drive the truck anywhere so my 10 year old son and i had to wait for an hour for a tow truck. after some research, i realize that this has happened to thousands of people. ford seems to blame incorrect torquing of the spark plugs, but most people blame a poor design in the small quantity of threads holding the spark plug. i can say that no one has touched the plugs in this truck except for a ford dealership when the plugs were changed at 75,000 miles. i am now stuck with an enormous repair bill of over $2000 for installation of a new head and coil pack (not to mention a tow bill and the stress of being stranded on the interstate and not owning a functional vehicle). if this is a design issue, then ford needs to at least make the repairs affordable. *tr
01/25/20091220001
 I have a ford f-150 2001 with triton 5.4 v8 i started my truck and heard a loud pop and then what sounded like a very bad exhaust leak. come to find out the back sparkplug on passenger side blew out. i had to have a new coil new plug and helicoil installed. *tr
05/01/20091
 2001 ford f150 spark plug blowout has left me without a vehicle and out of money now. according to my research this is a common problem among all ford v8's and v10's from 1999 to 2002. the problem is due to lack of threads in the aluminum heads (only four theads), and has resulted in several fires and extensive property damage. apparently all attempts at a recall and class action law suit have been met with relative disregard. despite the fact that ford redesigned their heads after 2002 to correct this problem they still refuse any assistance to customers who suffer due to their design flaw. apparently someone will have to die from the engine fire before anything will be done. and eventually someone will die, if they haven't already. perhaps a death due to this problem might force legal action. i'm currently looking at over $3000 worth of repair cost, the vehicle cannot currently be driven due to risk of fire. please refer to consumercomplaints.com for a list of thousands of individuals who have suffered because of ford's design flaw. *tr
03/05/20091900001
 I have 2001 ford f150. triton v8 engine. driving under very light load, going 35 mph the number 1 cylinder spark plug shot out and caused damage to the threads. *tr
01/02/200971000
 Tl*the contact owns a 2001 ford f-150. while driving 15 mph, the contact noticed that his vehicle would drive extremely rough. he took the vehicle to a local repair shop and they stated that the intake manifold and passenger side bolts in the engine had excessive rust. in addition, the intake manifold needed to be replaced at the cost of $600. the vehicle has not been repaired. the failure and current mileages were 71,000.
11/08/2007920001
 Intake manifold leak. plastic part cracked. i just had repair made and was told ford has a problem with this type of manifold. my truck is a 2001 f150 with 90,000 miles. *tr
04/10/20081905901
 Spark plug blow out on 2001 ford f150 4.2 v6. purchased the truck new in 2001 and recently replaced the engine because of the plug blow out. now the replacement engine is running bad and i think it is getting ready to happen again. *tr
05/24/20081070001
 Tl*the contact owns a 2001 ford f-150. while driving approximately 65 mph, the contact heard a knocking noise. he pulled to the side of the road and discovered that the front passenger side spark plug blew out of the head, busted the coil, and caused fuel to spill from the head. the current and failure mileages were 107,000. updated 08/14/09. *lj updated 08/17/09 *jb
05/16/2008850001
 I have a 2001 f-150 triton 5.4 liter ford with 85,000 miles on it -- it blew out the number 3 cylinder spark plug stripping the threads and breaking the coil pack. i heard a ticking sound for a few weeks prior and had it checked at a shop and they thought it wasn't a bad problem -- 3 days later it blew out the plug. *tr
04/18/2008610001
 During normal driving the spark plug in cylinder #3 blew out of the cylinder. this disables the vehicle. spark plug ejection is dangerous because fuel vapor starts coming out the spark plug hole, which is clearly a serious safety issue. the fuel vapor can be ignited by the ejected spark plug. the spark plug was the original installed in the engine from the factory. the blow out damages the spark plug hole threads and it also damaged the coil pack. repair is very expensive and requires a technician to tap a new hole and place a threaded insert in it. the problem is these type of repairs are not usually reliable. *tr
03/07/20081
 Spark plug blew out of my 2001 ford f150 with only 84,000 miles on it. *tr
12/17/200793549110/15/2005
 Spark plug ejected from cylinder head. *tr
06/09/200771000209/16/2006
 Was cruising in my ford lightning, when i heard a loud pop and then sounded like my engine was running off the headers. pulled over and had to catch a tow truck, to the shop. they told me my spark plug had shot out of the head. $1,100 bucks later it is back in the shop now and having the entire motor pulled cost not known but approximately 5-10 grand... *tr
03/20/200768200101/10/2002
 Ford - spark plug defect. while driving on the interst a spark plug popped out of its socket and broke the spark plug coil. i was in th middle of heavy traffic an ws very scared because i could not initially pull over due to the amount of trucks on the higway.i was boxed in. after i was able to pull over to the side of the road i opened the hood an found a spark plug stuck to a piece of plastic melted to it due to the hea). i also oundthe spark plug coil, with the spring hanging out of the rubber insulator, spaking against another piec of plastic.*ak i feel the is an extreme danger because: 1. i could have caused a major accident on the freeway. 2. the spark plug coil could have shocked meor even started something on fire. after researchingthe problem on the internet, i see that more and more incidents exactly like e are happening every day. ford refuses to admit there is a problemeven though they changed the design in 2004 and theprobem doesn't exit with spark plugs anymore. what needs to be done to get this problem resolved. does omeone have to die?
02/26/200779000208/27/2001
 My 2001 ford f-150 truck had a spark plug eject from the cylinder and hit the fuel rail while on the highway on 9-1-06 (70,000 miles on odometer). i had the truck hauled to nearest service center where they fixed the cylinder with a repair kit made for this problem. on 2-26-07 at 79 thousand miles another plug ejected with the same consequence. now the entire head has to be replaced at a cost of $3600 to me. *jb
05/30/200648000209/10/2001
 While traveling on a busy highway near my home my 2001 f150 blew a spark plug from the motor. this is the second time this has happened to me. the first at 37k miles and the second at 48k. the loss of engine power nearly caused a collision. i was in heavy traffic and in the passing lane at the time. this is a frequent occurence with this ford motor from what i can see on the internet. why is nothing being done to protect the consumer from this obvious design flaw? does someone have to die first?
01/26/2007120000401/12/2005
 Http://www.consumeraffairs.com/automotive/ford_spark.html please check out this link , it is in regard to a similar problem i am having please help!!!!!!!! *nm
10/25/2006119250107/20/2001
 Spark plug blew out of cylinder head while vehicle was traversing street. *nm
08/15/2006140000208/23/2001
 Spark plugs blow off the aluminum heads. *nm
05/01/2006980004
 For a few months after tuning up my ford f-150 with the 4.8 v-8, my truck started blowing spark plugs out of the motor while driving down the road. i brought this to the attention of ford and was told it was a common problem with this motor but they would not be responsible. i did my own research and found instances of people running off the road after their plug shot through their hood and scared them. *jb
10/18/2006127000105/02/2001
 Spark plug blowingout of cylinder head on a 2001 ford engine 5.4 v. 8. *nm
05/12/200440000104/04/2001
 Ford spark plug blowout. *jb
04/28/200687777104/30/2002
 My f-150 ford pickup truck engine made a loud pop and a series of pop noises after that in taneytown, md on 4/28/06. pulled over to side of road and shut engine off. opened hood and did not see anything, but smelled gas. started engine and saw a coil and wire flapping up and down. purchased new coil on 4/29, and attempted to replace. found spark plug from cylinder on the laying on the top of engine block. i attempted to drive home, but 3 miles down the road, experienced same condition. brought vehicle to crouse ford in taneytown, md. internet searches show that there are a lot of vehicles with the same problem. i contacted private auto repair center to correct. this has cost me over $6,900 thus far. i honestly believe that there is a design defect and a safety issue that ford motor company should be responsible for. there are countless cases of this condition in the triton engines (from my research) from 1999-2002. i believe ford motor company should be responsible to me, its customers, and the other potential failures from their poor engine design. the head is manufactured from aluminum, and the spark plugs only have 4 threads which is not enough to hold under combustion pressure. denial of this condition, in my option is consumer fraud. i am seeking reimbursement of total cost of engine replacement and all associated repair costs encountered from this negligence. i thank you in advance for any assistance you can provide. *jb
01/20/2006930001
 My 2001 ford f150 recently ejected a spark plug. i have had an ongoing problem with this truck, having it in the repair shop numerous times. approx. 2 weeks ago during normal driving, the engine blew a spark plug completely out. i received an estimate from a ford tech. of approx. $2000. i have purchased a kit to repair this myself. the company made the kit specifically for ford triton engine repairs, which shows this is a major problem. i estimate the total cost of my repair will be over $1000. *nm
12/14/200597650112/23/2000
 I have a 2001 ford f150 with a 4.2l v6 engine and at 97,500 miles it started to leak antifreeze. a mechanic told me that it is a problem that he has seen in many f150 trucks with the 4.2l v6. he said that the lower intake gasket as well as the timing cover gasket have to be replaced to fix this problem. *jb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
12/17/2007110000111/15/2001
 Spark plug blown out of cylenfar head (#3) 2001 ford f-150 5.4 triton. *tr
05/09/200741000111/15/2001
 01 f150 supercrew 5.4l with less than 41,000 miles. right rear spark plug blew out of head also breaking coil mounting bracket. dealer removed engine to attempt repair and found spark plug hole would not accept heli-coil. in process at this time trying to locate a new head. this truck has been well taken care of and with less than 41,000 miles, how was this possible! i have been a ford driver most of my life. but i will think twice before buying another ford. this problem is well documented and should be repaired under a recall. *ak
07/31/20061120001
 1 - was driving from tucson, az to my uncle's funeral in riverside, ca. outside el centro, ca plug blew out of the head on my 2001 ford f150 supercrew 4x4. i attempted to put another plug in but the threads were gone from the head so i went to the dealership. they took two days to repair so cost me a day of work and my kids an extra day of school. the did a helicoil repair at a cost of $498. *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
06/05/2010118042
 Tl-the contact owns a 2001 ford f-150. the contact started the ignition and light grey smoke emitted from the exhaust. the failure was intermittent and became progressively worse. the vehicle was taken to an authorized dealer on three different occasions for the identical failure. the catalytic converter and engine heat control sensor were replaced at the owner's expense. the failure continued after the repair was performed on the vehicle. the failure mileage was 118,042. js
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
11/22/2005119852111/30/2003
 While driving my 2001 f150 truck, the check engine light came on. i took my truck to the garage that does my auto work. they told me it was the egr pressure sensor. they replaced the sensor at a cost of $190.00. later i found out that ford had issued a service bulletin to have the sensor replaced and they sent letters to the owners to bring their trucks in to have the sensor replaced. since i am the second owner of the truck i did not receive the letter and since i had 119,852 miles on the truck ford would not fix it. ford knew of the defect, why should i have to pay to have a defective sensor replaced.*jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
06/09/200771000209/16/2006
 Was cruising in my ford lightning, when i heard a loud pop and then sounded like my engine was running off the headers. pulled over and had to catch a tow truck, to the shop. they told me my spark plug had shot out of the head. $1,100 bucks later it is back in the shop now and having the entire motor pulled cost not known but approximately 5-10 grand... *tr