Manifold/header/muffler/tail Pipe problems of the 2002 Ford Excursion

Was starting from a stop to make a left turn when driver heard a loud pop. There was a sudden loss of power and some smoke. The vehicle was towed and diagnosed. The #3 plug on the right bank has blown completely out and damaged the coil pack. A phone call to the dealer yielded no help other than we can have it towed there to be repaired, as it likely needs a new head. Some internet research and talking to other Ford owners definitely suggest that this is a design problem with the alum heads blowing out spark plugs, and the #3 r plug seems to be common. This could cause fuel/vapors to be exhausted and sprayed on a hot manifold and cause a fire. It sounds like there may have already been some fires attributed to this problem. This sound like a case where the dealer/Ford refuses to admit that it is a problem and fix it for owners. Before there are serious injuries from a crash or a fire, Ford should be compelled to fix this issue. Its unlikely that Ford will answer the call without pressure from NHTSA. There seem to be far too many of the same type of problems with this 5. 4l motor for it to be a coincidence.

Exhaust manifold bolts, rusted and broken off, right bank.

While driving my 2002 Ford Excursion on the interstate at about 65 mph, I heard a thump under the hood and then my engine began to make a loud clunky sound (almost as if there were no muffler). One of the sparks plugs had blown out of the engine! luckily, my Excursion was still drivable and I was within a few miles of my home and could park it until I could seek repairs on Monday. I did not take it to the Ford dealership (trust issues). I took it to tune-up 2000, where they told me the spark plug threads had stripped out causing it to blow form the engine. It had to be re-threaded, costing me $500. This puts my repair bills, for my less than four year old Excursion, at over $3500 in 2005. The entire transmission had to be rebuilt this summer due to a cracked transmission case.