Car Stall problems of the 2002 Ford F-150

I was driving my vehicle when I heard an explosion-type sound, similar to that of a gunshot. The sound startled me and caused me to veer off the road crashing into a bush on someone's front lawn. I re-started the vehicle and heard a very loud and rapid "popping" sound from underneath the hood, which became worse as I accelerated. The vehicle was also shaking violently as I attempted to drive home, which was only 1 mile away from where the incident occurred. When I arrived home I inspected the engine compartment and immediately noticed that the 2nd spark plug in on the driver's side of the engine (#6 cylinder) was blown completely out of the engine head. I contacted my local Ford dealer the next morning and was told to have the vehicle towed to their service department. Shortly after arriving, I was informed that "blown spark plugs" are a very common issue with the Ford triton 4. 6 and 5. 4 litre engines. I was advised that the spark plug hole would have to be re-tapped and a heli-coil kit installed. This work was performed on 06/08/2012 with a total cost to me of $449. 81, not including the cost of the tow. I was advised by the dealer's service department that Ford had issued the first of several TSB's (technical safety bulletins) to all of it's service departments across the us in March of 2006 informing their technicians of the defect in the engine's aluminum head and the increasing frequency of this "blown spark plug" issue. Included in this TSB were instructions on how to repair by using a heli-coil, which is not a Ford part, not covered under any warranty and not guaranteed to stay in place. A recall needs to be issued. Please see the link; I am one of thousands who have experienced this issue and I feel that those of us who have incurred unnecessary costs due to Ford's defect should be made whole. . Read more...

The contact owns a 2002 Ford F-150. The contact stated that while driving approximately 25 mph, the vehicle suddenly stalled without warning. The vehicle was able to be coasted off the road and was towed to a dealer. After diagnosis, the dealer advised him that a spark plug had blown through the aluminum head and needed to be replaced. The vehicle was repaired for the steel ring being placed where the plugs were stripped. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 65,000. Updated 03/05/lj updated 03/07/12.

Ford f150 2002 was having what we thought was a wheel balance issue. Day before sounded like lifters we needing adjustment (tapping) that seemed to get better as it drove. Was turning onto a highway type road, engine made a bang that sounded like it threw a rod, followed by loud pops. There was no smoke or oil. Immediately pulled over and cut the engine. Had to tow truck to dealer ($90). Ford dealer identified blown spark plug #3, and used a kit to install helicoil to allow replacement spark plug. They said induction cleaning was also necessary due to the non-firing cyl, plus all new plugs. Repair cost $950. Lost use of truck for two days, and then found out this is a known issue without a recall; and it could happen at any time on other spark plugs. Spark plugs original to vehicle and normal maintenance was conducted on the truck. Was advised I could have done nothing different to prevent this from happening. . Shocked and appalled to read of thousands of similar occurrence, and Ford even has a kit to repair their manufacturing defect.

In April of 2010 my F-150 truck "spit" a spark plug while traveling at freeway speed. This was a dangerous situation since it was during rush hour and many 18 wheel trucks were traveling down the I-5 at the time and were reluctant to allow a car to pull over. I had the truck fixed at a aaa approved repair station which removed the remaining spark plug, retapped the block, installed an insert and new plug. Then, the same thing happened again in October of 2010 to a different plug. Again I had the truck repaired in the same manner. The risk of fire and collision was directly caused by the failure of these spark plugs.

Well the events leading up to the failure. . . . There were none we were driving back home when all of a sudden pop and there goes my #3 spark plug. Well I was stranded for two hours or more until I got my truck towed to my house. The estimated price on a repair for that is $1700 to take the cylinder head apart and install an insert and that price is just for labor no charge on parts yet. This is a common problem that if you look online you will see that many people have the same problem. We need to make Ford stand up for their mistake before someone looses their life do to an open spark and fuel being present and exposed when the spark plug blows out.

Truck maintained according to manufacturer specs. While driving daughter to school, heard loud pop. Was able to make it to local repair shop. Blown spark plug out of #2 cylinder. With the use of helicoil repairs came to approx. $700. Less than 6 weeks later #4 cylinder blew spark plug while driving 65 miles per hour on the freeway. This time (after much research of similar complaints) installed longer thread spark plugs suggested by Ford parts department. This time repair costs were $800. 00. If Ford has made a special kit and new longer spark plugs for this "problem" isn't that a subtle admission or guilt/responsibility. What ever happened to doing the right thing. . . Admit your mistakes and take care of these repairs. "built Ford tough" my eye!! my next truck will be a Toyota. . .

While driving down the road, I heard a loud explosion and the engine began running rough. I pulled over and opened the hood. The explosion had dented the inside of the hood. I found a broken coil laying on top of the engine, and the corresponding spark plug laying beneath the engine. I took the vehicle to a mechanic, who re-threaded the spark plug hole and installed a new spark plug. The vehicle performed as usual for about six months, and then the same exact situation occurred, involving the same exact spark plug. The second occurrence, the plug and coil were so damaged that the head could not be re-threaded and repaired. After researching this issue, I found that dozens of other owners have experienced the same problem, which is due to an engine and/or piston defect. The second occurrence required drilling out the affected head, tapping it, and installing a helicoil before the spark plug could be replaced. I am very concerned about this issue, since in addition to the expense and inconvenience this manufacturing defect has caused me, it is extremely dangerous as well. While I have not had an engine fire, other owners of this make and model have reported engine fires.

I was returning from work on 1/2/08 when my 2002 Ford F-150 (triton 5. 4l) began to pop and run rough, I smelled gasoline in the cab of the truck and pulled right over, upon looking at the engine I noticed the #3 plug lying on top of the engine, it had blown out. This plug was factory installed and had never been removed from the engine.

#3 s parkplug blew out of head and also broke coil on plug. Ford service shop installed helicoil to fix problem and replaced coil on plug. Also had Ford service look at noisy ac blower motor fan and it was also bad. Vehicle is a 2002 Ford f150 supercrew 5. 4l with only 28,500 on it. Did not keep parts. Vehicle out of warranty but I called customer relations and they only covered about 1/3 of cost to repair spark plug problem and none of the ac blower.

2002 Ford F-150 5. 4 liter engine 66,xxx miles driving on city street, approximately 35 mph, 3rd spark plug on passenger side blew out towed to repair shop, heli coil insert installed no old part available.

I currently own a 2002 Ford F-150. At about 70,000 miles a spark blew out on the drivers side. This was the original plug. Had to have helicoil installed. Prior to this incident, my 2001 expedition had the same problem. This was also the original plugs, but this motor only had 60,000 miles. Unfortunately, the Ford dealer I had it towed to would not perform helicoil, so I had to replace the head. They said Ford did not recommend helicoil. So I have owned 2 Fords within 1 year of each other and both have had the exact same problem with plugs. It's apparent that Ford has a design flaw. I heard from a Ford dealer that the newer body style of F-150 has had a correction in the thread design in the heads.

Vehicle experienced sudden stalling at various speeds. Took vehicle to dealer for checkup, but the cause was undetermined.

While driving the vehicle stalled without warning. The dealer could not determine the cause of the problem.