Loud Engine Noise problems of the 2003 Ford Expedition

We were driving with the kids headed home, going about 45mph and loud noise and smell of fuel, we pull over lifted the hood and saw my coil pack busted off, we drove the rest way home to ark it, and looked again. The spark plug arched inside the head and busted the coil pack bolt and all. Shame that we tried an insert to repair it and doesnt work. I have been stressing this considering im a single mom of two that have disabilities and we have these appointments left and right and its hard walking across town all the time. This problem needs fixed by Ford. I researched and its a known problem cause the cheap aluminum heads. We really need our vehicle. . .

The contact owns a 2003 Ford Expedition. The contact stated that while driving approximately 55 mph the vehicle began to smoke inside of the engine compartment and vehicle. The vehicle also made a loud noise and would stall. The vehicle was towed to a Ford dealer who stated that a spark plug melted into the engine and that the vehicle needed a new engine. The dealer stated that the contact would be responsible for the repair cost. Ford motor company stated that there was nothing they could do. The vehicle was not repaired. The failure and current mileages were 88,546.

Spark plug had blown out of its place in the engine. At first, I had the check engine light on and I had promptly taken to the shop (ase cert. ) but the light didn't come on any more. After the service man ran the test some time later, nothing appeared to be wrong. A day or so later, I was hearing a "clicking" sound under the hood, later, I had lost a spark plug. Which by the way is a horrible noise! I was told by the service technician that it was a problem with Ford vehicles.

Spark plug ejected from the engine causing the coil to brake as well, and the whole car to smell of gas. This happened once in April, and again the other day (may 17th), on a different plug. It has caused me to lose work, and my mechanic installed a repair kit with a new spark plug. It was $200-$300 for each repair. Ford says its not a problem, but my mechanic has had other cases like this, and stated Ford issued a service bulletin on how to fix the problem. I have contacted Ford, asking them to at least check my other plugs to make sure they are tight, but they were unhelpful. There was no warning in either case. The truck drives fine, and then suddenly starts making a loud noise as its driven, and the whole truck smells of gas. These are the original plugs, and the truck has 78k miles on it. I believe the head needs to be replaced so it doesn't keep happening. I went on different car problem websites, and this seems to be a problem with this model truck.

I have park my truck and went to have dinner with my family and upon my return when I start my truck. The engine make a loud sound and spark plug blow out from the engine.