Manifold/header/muffler/tail Pipe problems of the 2002 Ford F-250

Leaking head gaskets on 2002 Ford f250 truck with 5. 4l engine allows oil to leak onto starter and exhaust manifold creating safety hazard. This is a known problem with this type engine.

I own a 2002 f250 v10 with approx 84,000 miles. I was just driving along and the spark plug from the # 8 cylinder blew out. I had to retap it and put a helicoil in it. The spark plugs were the original spark plugs and have never been replaced. I have seen numerous complaints of the same problem on kline. It is definitely a manufacturing defect. Also I need to replace the exhaust manifold bolts on the same cylinder heads. This is another problem I have found numerous complaints about online.

I purchased an f250 2002 triton v8 super duty mid year 2007. Less than a year after the purchase a spark plug blew out of the manifold. This all happened under normal highway driving conditions. The dealer put in an insert, rethreaded it and replaced spark plug. Almost a year to the day it happened again. So now #2 & #4 have blown out. On 5/30/09 a third one blew out. All on the left side (passenger side) of the manifold. So now #2, #3 and #4 have blown out. I researched the incident online and have found 500 other cases. I'm curious how many are really out there that weren't reported. I've been fortunate because in some cases the spark plug blew through the hood or damaged the manifold. I do however wonder what damage is occurring each time it happens. How many reports or how many vehicles does it take before there's a recall? even though I have extended warranty I've been charged a deductible each time and now face a third if my warranty is still good. I have one more plug on that side that hasn't blown yet and since this one was only 7 months since the last one I suspect I'll be paying again. I saw online where it was suggested as a piston problem.

2002 Ford f250 crew cab 4x4 short box, 5. 4l v-8 gasoline engine just under 92000 miles. On 7/21/2008 merging on the expressway under heavy acceleration, a loud bang with spring popping sound was heard from the engine followed by the distinct odor of exhaust and unburned gasoline. Verified throttle control and continued to drive with loud noise coming from engine. Drove 4 miles to work to safely inspect the problem. Noted that the exhaust y-pipe was separated from the drivers side exhaust manifold. Assuming that it was just a failed manifold bolt, drove ~20 miles to the dealership to have it looked at. Received the call that the number 6 spark plug was ejected from the head. Upon the dealerships inspection, found that the threads were stripped out of the head. The spark plug then arrested in the ignition coil which was separated from the head due to failure of its mounting flange. The ignition wire held the coil and plug on the engine. There was zero gap noted on the spark plug electrode with anti-seize compound on only about . 5" of the spark plug thread. Thus suggested that only . 5" of thread engagement was present from the factory original plugs (I. E. The spark plugs were not replaced since the recommended replacement interval is 10 years 100000 miles). Advised that at a minimum a head needed to be replaced, but that an engine may be a better economical choice so that both heads are replaced and this design issue could be overcome (the newly remanufactured engine is supposed to have larger thread engagement at approximately . 75"). Engine replaced to insure that this failure would not occur on one of the other cylinders in the head that would not be replaced.

Two manifold bolts snapped off each side of my 02 6. 8 liter engine. The rest are horribly rusted. The truck has only 37000 mi on it. There has been a TSB concerning this, but it is a huge and common problem. There needs to be a recall for the people out of warranty,as it does concern emissions and the leaking of exhaust gases from before the cat.

I heard a sound coming from my exhaust and after looking over the exhaust I notice that I had some exhaust manifold studs and nuts that hold the exhaust manifolds to the engine heads had either broken or snapped off causing the exhaust leak I heard. After seeing that I had an issue with the exhaust studs I took my 2002 Ford F-250 super duty with 6. 8 liter engine to the dealership were I have my service work done and had 1 of the service technicians look at the issue. I was told at the dealership that Ford motor company knew of the problem with the studs and nuts that was used when my truck was manufactured and knew of that problem since 1997 through 2005. Yet Ford motor company will not do anything to resolve this issue. From 1997-2005 Ford motor company used steel studs and nuts for attaching the exhaust manifolds to the enines on there 5. 4 liter and 6. 8 liter engines. That's a period of 9 years of using parts that were faulty for use in manufacture. The failure of these exhaust studs and bolts can and will cause the exhaust manifolds to warp thus the consumer having to replace the exhaust manifolds as well. Also with the failure of the faulty exhaust studs and nuts could cause engine problems like warped valves, or head damage, which could cause engine to blow or lock-up. I have notified Ford motor company on 3 occasions and have met with the same response that they will do nothing to amend the issue at hand. They have a technical service bulletin that they have available which requires that the use of stainless steel studs and nuts in service for the 5. 4 liter and 6. 8 liter engine. As well as replacing the exhaust manifold on the affected bank(s), exhaust manifold gaskets. Ford motor company failed to notify the consumer while the vehicle was under warranty so repairs could be made.

I have a 2002 Ford sd with the 6. 8 v10 with 42,000 miles on it. When I took in for a noise from the exhaust I was told that I had 4 manifold bolts rusted off and more where ready to break. I had the repair work completed at a cost of $3200 which I had to cover. I was told that this is a common problem but Ford is not standing behind this problem. While they were working on the truck they found the power steering pump coming off and looking in to that it was found that a bolt was broken off in the frame. The repair shop told me that they have done many of them just like mine. I have owned 10 new Ford products in the past 12 years and this will probably be the last.

2002 Ford F-250, exhaust leak developed just after 50,000 miles. Right side manifold had split. Ford refused to warranty it, even though it was only 4 1/2 years into a 5 yr/ 50,000 mile emissions warranty. There is a recall on the mounting studs that changes them to stainless steel. They have a problem with the factory studs rotting out. They also have made improvements to the holes in the manifold. They were enlarged to resist cracking. Both manifolds had to be replaced along with the broken studs. All old parts are in my possession. Otherwise the truck is in like new condition.

2002 Ford F-250 super cab spark plug blew out of cylinder head. Just driving down the street and all at once there was a loud bang like a big hole blew out of the muffler. Shut the engine off, pulled over and tried to determine cause. Drove truck another couple of miles to repair shop. The repair bill was over $2,000. The repair shop states they have had at least 6 of these situations in the last 2 months. We believe this is a defect in this truck - the truck has 61,700 miles on it and it is too early to experience this kind of difficulty.

I have a 2002 Ford F-250 super duty pickup truck with a v-10 engine. It has approx. 63,000 miles and is subsequently 'out of warranty' (3/36,000). On July 9, 2004 I heard a brief tapping noise and a pop then a loud noise like an exhaust manifold leak. Immediately upon hearing this noise I shut off the engine and called a tow truck, as I am not a mechanic and did not want to create further damage. When the mechanic arrived to tow my truck he observed that a spark plug had been blown out of the cylinder. I informed him to tow it to his lot until I could decide what to do. The next dy I had the tow truck company bring my truck to the Ford dealership I purchased it from. Today after the dealership's mechanic inspected my truck they informed me that the cylinder head was broken and I would be liable for the $3,700. 00 repair. What I find distubing is my scheduled spark plug replacement service interval: Ford recommends 100,000 miles before replacement. How would I ever know that the speark plug was not installed properly at the factory prior to the scheduled service? additionally, had it not blown out on its own, who knows what other damages would have gone unchecked. I have researched this particular defect on the web and have found not less than 100 people thus far with the exact same complaint. Additionally , I have found numerous people that this has happened to more than once on the same engine. I stopped researching because I feel this is suffucient supporting documentation of my complaint. If necessary, I will be happy to furnish this documentation for you. I have found this problem to be inherent in all v10 Ford engines since 1999. I have also found that Ford is aware of this problem and has issued a technical service bulletin to all of their dealerships describing this particular repair procedure.

Complaint regarding problems with Ford v-10 engine. The consumer started a petition with other Ford consumers who have experienced problems as well. Additional problems the consumer experienced were: brief tapping noise and a pop, then a loud noise like a manifold leak, the mechanic observed a spark plug had been blown out of the cylinder and the cylinder head had broken. The consumer's cell# 845 0 438-3527.