Ejected sparkplug 2002 4.6 Ex

[WilliamsRpTx]

Please bare with me as this is my first post here.
I have a 2002 Explorer 4.6 Eddie Bauer 2WD with about 143,000 miles. It has been running great. This morning when my wife was going to work, she started it and everything seemed normal for a second or two. Then there was a loud bang/pop that woke the neighbors and it ran rough for a couple seconds before she could kill it. It was dark, so we didn't see any smoke, however it did have a slight burning smell. I checked the engine compartment from above and below as best as I could in the dark with a flashlight, but could see no damage or leaking fluids. After work this afternoon I will be inspecting it further. Any suggestions would be greatly appreciated.

Update:
After searching Google and 5 minutes inspection, I found out a spark plug was ejected. Has anyone else had or seen this problem? How serious is it going to be? Will I have to replace the head?

 

[rrgone]

Hi there, welcome aboard.

This ejection of a plug from the Ford 4.6 l engine comes up in here from time to time. It seems to be more rare in the Explorers than Mustangs and F-series trucks. Anyway, there are a few different types of inserts that you can use to repair the threaded hole. Here's a link I found pretty quickly. There are more in here I know...
http://www.explorerforum.com/forums/showthread.php?t=334632

You can probably find videos on you tube if you look around. Google 'time sert'. That is one brand of insert. I've never had to deal with this issue so I have no first hand experience. Please post back with your results. Good luck.

 

[WilliamsRpTx]

Thanks. I'm currently working on putting in a helicoil. Of course it couldn't be a front one, and the long chamber leading down to it does not make it any easier.

 

[Bobmbx]

I've been messing with cars since the early '70s, and I've never heard of this happening.

I've either not been paying attention, or its something new due to lighter metals being used in these fuel-efficient engines nowadays.

Anybody know why this happens?

 

[WilliamsRpTx]

From my understanding, they went extremely cheap with the threads on 97-05 or later 4.6, 5.4, & 6.8 heads

 

[WilliamsRpTx]

Put it all back together last night, let it sit a couple hours for the threadlocker to set, and fired it up. There was a tapping and some shaking like a plug was loose but I couldn't tell where it was coming from. Pulled the plug back out (thankfully the insert stayed put) and it looked fine so I put it back again. Started it back up, had tapping and shaking for about 15-20 seconds, then it smoothed out. My wife drove it to work this morning with no trouble. I told her to baby it as much as possible, though.

 

[rocco123]

Common issue. had my first plug blow out 150 mi from home. I used the dorman 42025 kit, but knew it wasn't sealing well. When I got home I pulled the adapter back out and found it wasn't seated because the corners of the adapter flats were hitting before the adapter was able to fully thread in (corners hitting plug bore). Ground off the flats about 1/2 inch back and reinstalled using JB weld. Felt the threads cutting as it went in and now no more blow-by. Quick & easiest fix by far, but now have to buy the HT1 plug but how often will I need to pull the plug anyhow. New accel coils on order. Just want to get the word out that if the Dorman kit doesn't seem to seal the hole, remove it and see if you need to fit the adapter by grinding off the corners a bit.

 

[fireftr]

Ejecting plugs

Just another one of Ford's better ideas. "Quality, Job 1", my ass! My '05 "Exploder" just launched one @125k. Was going to put new ones in this summer, but it had to pay $300 +$80 tow to have a mechanic do it. This is the last Ford I'll ever own. This repair, real axle bearings, rebuilt tranny...what's next? Don't mind usual maintenance issues, but engine,drivetrain and tranny flaws are unacceptable. Steering wheel radio controls never worked correct from the day I took delivery. Lug nut covers break off (same crappy lug nuts as on my '89 Sable!). I'm getting rid of this and buying something RELIABLE. I don't think that's asking too much, is it? I work too hard for my money to waste it keeping a piece of crap vehicle together.