Manifold/header/muffler/tail Pipe problems of the 2000 Ford Excursion

I was driving my Excursion aeound 25 mph and as I accelerated to 35 mph I heard a loud bang and thought my exhaust manifold may have cracked or came loose. After further investigation I found the spark plug wire and spark plug were blown out. Called local mechanic and said I needed to bring it to Ford for approx 4k, Ford would replace the head. I went on line and purchased a kit, Ford is aware of the problem with the spark plug being blown out of the head but will not recall the truck. Note that this is affecting many vehicles, not only Ford. This is a huge issue and very unfair that the manufacturer of the head is getting away with the poor quality control and the fact that they are not correcting the issue for the consumer.

A spark plug blew out of my 2000 Ford Excursion today on my way home. It was a loud bang, I thought the exhaust manifold cracked or muffler went. Apparently this is a common problem that Ford will not repair. It will cost about $4500. To fix. I am very surprised that I did not hear this on the news, it has happened to many Ford owners but never heard about it until I had this issue. It is very unfair that it is a common problem with Ford and the government does not enforce a recall. Ford recalled but did not correct the cruise control defect that could cause a fire. Fire. . . That is enough reason to recall the vehicle.

I own a 2000 Ford Excursion with a v10. While driving home from my son's track meet in a construction zone on i94 in mount clemens michigan during rush hour I had a spark plug blow out. We (my wife, my son and I) were moving about 10 miles an hour in the construction traffic when we began to slowly speed up. I accelerated and boom, there was a very loud sound of knocking. I nearly hit the dividing wall it scared me so bad. I was able to pull over about 150-200 feet ahead through the construction barrels. I opened my hood and discovered that one of my coil packs was sticking up a few inches and broken. I called my insurance company (usaa) for roadside assistance. Within an hour and a half they sent a tow truck and had me towed (about 7 miles) home. The next day I was able to better inspect what had gone wrong. The motorcraft spark plug had completely un-threaded itself and the compression of the motor turned the spark plug into a projectile that completely demolished the coil pack. The coil pack snapped from its retaining bolt and was beating against my fuel rail. Luckily I was able to pull over as soon as I did because I could only imagine if I had been in an area where I was traveling the actual 70 mph speed limit and the damage to my fuel rail could have been disastrous possibly causing a fire. I contacted russ milne Ford in clinton twp michigan about this issue and they stated that it would cost over $1000 to replace the head and that it was caused by the threads on the head or improper torquing of the spark plug. I found that amazing since I had my truck serviced by them about a year before because of an slight engine knock that I had on the passenger side of the motor along with a few other minor things. They never were able to find the cause of the "engine knock". Unfortunately for me the engine knock was a sign of the pending failure that I wish had been discovered before the blow out. No repairs yet.