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Which Ford engines have spark plug problems?

Several Ford engine models have been known to experience issues with their spark plugs, leading to various problems for vehicle owners. This article will provide a detailed overview of the Ford engines that have been affected by spark plug problems.


Ford 4.6L and 5.4L V8 Engines


The Ford 4.6L and 5.4L V8 engines, commonly found in Ford's F-150, Expedition, and other popular models, have been plagued by spark plug problems for years. These engines are prone to spark plugs becoming stuck or breaking during removal, often leading to costly repairs.



  • The spark plugs in these engines are designed to be "long-life" and can last up to 100,000 miles, but in many cases, they become seized in the cylinder head, making them extremely difficult to remove without damage.

  • When the spark plugs break during removal, the remaining portion can become lodged in the cylinder head, requiring extensive disassembly and repair work to extract it.

  • This issue has been a persistent problem for Ford, leading to numerous customer complaints and class-action lawsuits over the years.


Ford has attempted to address the spark plug problem through various service bulletins and technical service updates, but the underlying design flaw continues to plague these engines.


Ford 6.8L V10 Engine


The Ford 6.8L V10 engine, commonly found in the Ford Econoline and F-Series Super Duty trucks, has also been known to experience spark plug issues. Similar to the 4.6L and 5.4L V8 engines, the spark plugs in the 6.8L V10 can become stuck and difficult to remove, leading to potential damage and costly repairs.



  • The spark plugs in the 6.8L V10 engine are designed to last up to 100,000 miles, but in many cases, they fail prematurely or become seized in the cylinder head.

  • When the spark plugs break during removal, the remaining portion can become lodged in the cylinder head, requiring extensive disassembly and repair work to extract it.

  • Ford has issued service bulletins and technical service updates to address the spark plug problem in the 6.8L V10 engine, but the issue continues to persist for some vehicle owners.


It's important for Ford owners with these affected engine models to be aware of the potential spark plug problems and to follow the manufacturer's recommended maintenance schedule to help prevent these issues from occurring.

What Ford engine blows out spark plugs?


Ford 4.6, 5.4 and 6.8 modular engines are prone to spark plugs being blown out of the cylinders due to the aluminum threads failing.



What year Fords had the bad spark plugs?


If you are the owner of a Ford truck with a three-valve (3V) modular V-8 or V-10 engine built from 2004 thru 2007, you have either faced the misery of broken spark plugs-or you will.



What years did the Ford V10 have spark plug issues?


One of the most notorious issues with early V10 engines (1999 – 2005) is the tendency for spark plugs to blow out of the cylinder head. This problem stems from a combination of design choices: Material Mismatch: Ford uses a cast iron engine block with an overhead cam aluminium cylinder head design.



What Ford engine has spark plug issues?


One of the common issues of the modular platform was its tendency to blow out spark plugs. This issue happened the most on the 5.4 Triton from 1997 to 2003. During this era, the motor commonly powered the F-Series pickups, E-Series vans, and the Expeditions/Navigators.



How often does Ford recommend changing spark plugs?


every 30,000 miles
Most spark plugs should be inspected every 30,000 miles or so, with replacements often being necessary around the 60,000-100,000-mile mark, but cleaning the area around them and pulling them out for a wipe-down can benefit several drivers.



How to prevent spark plug blowout?


How to Prevent Spark Plug Blow Out: Ignition Problems Solved

  1. A spark plug blow out occurs when the spark plug is fastened too tightly or not tight enough to the engine plug.
  2. Check the Torque.
  3. Install the Plugs Correctly.
  4. Listen for Ticking.



What year to avoid Ford V10 engine?


Worst Years of Ford V-10 to Avoid

Worst YearIssues
2001 Ford V-10Poor mileage Gear shifting problems
2003 Ford V-10Leaks through the PCV hose cracks. The exhaust manifold rots and breaks Exhaust leaks
2017 Ford V-10Compression loss-induced cylinder misfires Gear-shifting problems



What year is 5.4 to stay away from?


Its the 24 valve (3 per cylinder) you need to avoid. They were produced from 2004 to 2010 when it was replaced by the 5.0L V8 they call Coyote.



What is the Ford class action lawsuit spark plugs?


The Ford class action lawsuit alleges that the following vehicles with 5.4-liter 3-valve engines contain defects that cause the spark plugs to become stuck and sometimes break in the engine during the removal process: 2004-2008 Ford F-150 trucks. 2005-2008 Ford F-250 trucks. 2005-2008 Ford F-350 trucks.



Does Ecoboost have spark plugs?


For Ford Ecoboost engines, it is generally advised to change the spark plugs between 20,000 and 40,000 miles. However, this interval can vary based on driving conditions and any performance modifications made to the vehicle.


Kevin's Auto

Kevin Bennett

Company Owner

Kevin Bennet is the founder and owner of Kevin's Autos, a leading automotive service provider in Australia. With a deep commitment to customer satisfaction and years of industry expertise, Kevin uses his blog to answer the most common questions posed by his customers. From maintenance tips to troubleshooting advice, Kevin's articles are designed to empower drivers with the knowledge they need to keep their vehicles running smoothly and safely.