Seven problems related to engine clicking and tapping noises have been reported for the 1999 Ford F-150. The most recently reported issues are listed below.
The contact owns a 1999 Ford F-150. The contact stated while driving 30 mph he heard a popping sound in the engine, followed by loud, repetitive clicking or popping sounds. The contact pulled over to examine the failure and the number 4 cylinder had fractured, the spark plug also blew out of its proper position. The contact took his vehicle to the closest independent mechanic. By the time the contact reached the mechanic the vehicle was overwhelmed with a strong persistent odor of used gasoline. The mechanic stated the number 4 cylinder spark plug did blow out. The vehicle was not repaired. The manufacturer and dealer have not been alerted. The VIN was not available. The failure mileage was 190,000.
The contact owns a 1999 Ford f150. The contact started the vehicle and heard a popping noise coming from under the hood. The contact then inspected the vehicle and found that the spark plug was spewed from the engine . The vehicle was towed to the dealer. The dealer stated that the spark plug needed replacing. The vehicle was not repaired. The manufacturer was contacted and advised that the vehicle was not under recall. No further assistance was provided. The failure and current mileage was 112,000.
While driving 45mph on suburban two lane highway I heard a loud bang and subsequent rythmic popping sound accompanied by an engine misfiring. Upon inspection I found the # 4 cylinder spark plug lying on the valve cover; un attached to the cylinder head. The mechanic found the threads "blown out" of the head and had to utilize a heli-coil kit to repair. The spark plug was a motorcraft original equipment part. This seems to be a prevalent problem with the triton 5. 4 liter engine. I suspect the problem originating from undue stress fractures in the aluminum head after continued use and inherent thermal differential rates (expansions/contractions) of the two different metals; I. E. Steel spark plug vs. Aluminum alloy head. Poor engineering !! I am the original owner of the f150 with 140k miles.
When I started my vehicle their was a loud popping noise, further investigation showed the #2 cylinder coil was jumping up and down. When I pulled the coil out the spark plug came with it. The aluminum engine head had stripped out the threads that hold the spark plug. Further dealing w/ Ford dealership, as to how to fix the problem, is to replace the head at a cost of 2500. 00 plus.
Manufacturing defect - plug thread failure vehicle is a 1999 Ford F-150 4x with 5. 4l triton and approx. 45,000 miles. While unaggressively accellerating at normal highway speeds the engine lost power and a loud popping sound could be heard. The vehicle was immediately pulled to the side of the highway, turned off, and towed to a repair facility. No injury or crash occurred. Investigation indicated a spark plug and coil had been ejected from the head. The plug was the 2nd from the front on passenger side. The threads in the head were stripped such that a new spark plug could not be seated. A helicoil was installed for approx. $300 and loss of vehicle for a week, but it failed after approximately 3 months. This failure was evidenced by engine misfire, power loss and sluggishness. Investigation revealed that same plug was not firing, and was not able to be removed because the helicoil threads were also stripped. The head was replaced at a cost of $3,626 with and additional 2 weeks lost vehicle use (2 comparable quotes from reputable auto repair providers were obtained). Repair time was longer than usual as the part had to be ordered from out-of-state and expedited shipping was deemed too expensive. At this time, however, the engine misfires continuously at idle and frequently at highway speeds. The vehicle is currently in the shop for a 3rd time to investigate this continuing condition.
While driving at 65 mph, suddenly there was a popping noise, then the vehicle stalled. The spark plug had came out the engine cylinder head. This occurred because of a design flaw, there was insufficient tread to hold the spark plugs. The cylinder head was replaced.
Ford F-150 XLT 57,000 miles - spark plugs stripped, and destroy spark plug. Noticed hissing sound from under hood when engine was just turned off. Ticking sound when first starting engine. Took vehicle to local Ford dealership for servicing. No warranty support. Claims to never hear of problem, even though f150-online forum has over 100 such incidents reported.