2001 Ford F Series Engine Problems

SPARK PLUG EJECTED FROM THE ENGINE BLOCK, AS VEHICLE WAS MOVING ON A HIGHWAY. DISABLED, NEEDED A TOW. REPAIR VERY EXPENSIVE. *TR

NHTSA ID

10928820

Incident

Nov 21, 2016

Mileage

150,000 mi

SPARK PLUG BLOWN OUT OF HEAD. SPARK PLUG #7 BLEW OUT 9 MONTHS AGO. NOW PLUG #8 BLEW OUT. MECHANIC SAYS IT'S DUE TO POOR DESIGN OF ALUMINUM HEAD AND INSUFFICIENT THREADS. BOTH TIMES, THIS HAPPENED WHILE COASTING AT A SLOW SPEED (< 30 MPH).

NHTSA ID

10916233

Incident

Oct 14, 2016

Mileage

109,000 mi

THE SPARKPLUG BLEW OUT FOR THE SECOND TIME. THE FIRST TIME WAS ABOUT 9 MONTHS AGO. RUNNING FINE THEN ABOUT 40 MPH THE PLUG BLEW OUT

NHTSA ID

10908389

Incident

Sep 17, 2016

Mileage

106,000 mi

MOTOR EJECTED #3SPARK PLUG ON PASSENGER SIDE. *TR

NHTSA ID

10626020

Incident

Aug 18, 2014

Mileage

147,000 mi

THE PLUGS BLEW!! THIS HAS HAPPENED REPEATEDLY AND AS OF NOW(7-2-2014) ALL HAVE BEEN REPLACED. IM SURE THAT WILL START AGAIN BUT THIS IS QUITE AN EXPENSIVE PROBLEM. MY TRUCK HAD 8 PLUGS...THANK GOD THEY DON'T ALL BLOW AT ONCE!! *TR

NHTSA ID

10607896

Incident

Aug 18, 2011

Mileage

138,000 mi

SPARK PLUG BLEW OUT OF ENGINE CAUSING FAILURE. ENGINE. *TR FIRE

NHTSA ID

10446872

Incident

Feb 6, 2012

Mileage

156,000 mi

2001 FORD F150 CAUGHT FIRE IN THE MIDDLE OF THE NIGHT AND WAS COMPLETELY DESTROYED. VEHICLE HAD NOT CRANKED IN OVER 24 HRS., AND NO KEYS WERE IN THE IGNITION. *TR

NHTSA ID

10284397

Incident

Sep 16, 2009

Mileage

47,000 mi

ON MULTIPLE OCCASIONS I HAVE BEEN DRIVING AND HEARD A LOUD BANG AND FELT THE MOTOR STARTING TO SHAKE AND LOSS OF POWER TO THE VEHICLE. UPON INSPECTION, I HAVE NOTICED THE COIL PACK OF MY 2001 FORD F-150 SITTING ON TOP OF THE MOTOR. I HAVE REPLACED TWO COIL PACKS TWICE EACH. IT IS GETTING COSTLY TO REPAIR AS IT COSTS $50 PER COIL PACK. I HAVE RETAPPED THE HOLES BUT THE PROBLEM KEEPS OCCURRING. I AM A DIVORCED FATHER OF A 2 YEAR OLD SON. I CAN'T AFFORD TO KEEP REPAIRING THE PROBLEM. *TR

NHTSA ID

10253733

Incident

Jan 4, 2009

Mileage

100,000 mi

#3 SPARK BLEW OUT OF ENGINE HEAD AND BROKE SPARK PLUG COIL IN THE PROCESS. THIS WAS AN ORIGINAL FACTORY INSTALLED SPARK PLUG. *TR

NHTSA ID

10235880

Incident

Jul 14, 2008

Mileage

83,577 mi

WE OWN A MOTOR HOME, BUILT ON A FORD INCOMPLETE VEHICLE CHASSIS, POWERED BY A FORD V-10 TRITON ENGINE. THE FIRST ENGINE BEGAN TO SPIT OUT SPARK PLUGS AFTER REACHING 75,000 MILES ON THE ODOMETER. THIS OCCURRED ON FRIDAY, JANUARY 27, 2006, ABOUT FORTY MILES EAST OF KINGMAN, ARIZONA. AFTER SPENDING MONEY TO GET THE PROBLEM DIAGNOSED AT A GOODYEAR DEALERSHIP IN KINGMAN, ARIZONA, WE HAD TO ORDER A SPECIAL REPAIR KIT FROM BARIL ENGINE REBUILDING COMPANY IN GREEN BAY, WISCONSIN, PAYING FOR THE SHIPPING BOTH WAYS. A MECHANIC RESLEEVED THE CYLINDER. AS I HAD TO MAKE A SPEAKING ENGAGEMENT, WE HAD TO DRIVE FOR CLOSE TO 1,000 MILES WITH WRETCHED FUMES AND HORRID NOISE. THE SECOND SPARK PLUG WAS SPIT OUT ON FRIDAY, FEBURARY 10, 2007. AS I HAD ANOTHER SPEAKING ENGAGEMENT, WHICH IS HOW I MAKE MY LIVING, WE HAD TO DRIVE TO PENSACOLA, FLORIDA, AND THENCE LAFAYETTE, LOUISIANA, BEFORE ANOTHER REPAIR KIT WAS RENTED TO BE USED BY YET ANOTHER MECHANIC. THE THIRD SPARK PLUG WAS SPIT OUT TWO WEEKS LATER, ON MONDAY, FEBRUARY 26, 2007, AS WE WERE DRIVING FROM PENSACOLA TO LAFAYETTE. WE RENTED THE TOOL KIT FROM BARIL ENGINE REBUILDING COMPANY ONCE AGAIN. THIS ORIGINAL FORD V-10 TRITON ENGINE DIED ON THURSDAY, APRIL 19, 2007, ON INTERSTATE 80/94 JUST EAST OF MILE MARKER 160. TWO CYLINDERS HAD LOST COMPRESSION ENTIRELY. NO ONE AT TERRY FORD LINCOLN MERCURY IN PEOTONE, ILLINOIS, COULD EXPLAIN WHY THIS HAD HAPPENED. WE HAD TO RAISE $9,000 TO PAY FOR A NEW ENGINE AND ITS INSTALLATION. THE ENGINE HAD BEEN WELL MAINTAINED. THE REPLACEMENT ENGINE HAS ALSO BEEN MAINTAINED WELL. DESPITE THIS FACT, HOWEVER, THE ENGINE SPIT OUT ITS FIRST SPARK PLUG, JUST 19,000 MILES AND THIRTEEN MONTHS, EIGHT DAYS AFTER ITS INSTALLATION, AN INCIDENT THAT OCCURRED THIS AFTERNOON, WEDNESDAY, JUNE 3, 2008, AT EXIT 22 OF THE NEW YORK STATE THRUWAY IN SELKIRK, NEW YORK. *TR

NHTSA ID

10229984

Incident

Jun 3, 2008

Mileage

19 mi

4 MONTHS AGO SPARK PLUG #3 UNEXPECTEDLY "LEFT THE ENGINE" DESTROYED THE COIL-ON-PLUG AND STRIPPED THE CYL. HEAD. ~2500 MILES LATER #6 PLUG AND COIL....SAME THING. *TR

NHTSA ID

10226403

Incident

Apr 29, 2008

Mileage

112,000 mi

I EXITED ON I-75 ONTO SR 200, TRAVELED 100 FEET APPROXIMATELY 20 MPH, HEARD POPPING SOUND LIKE BASEBALL CARD IN SPOKES OF A BICYCLE WHEEL. HAPPENED SATURDAY NIGHT WHILE BRINGING MY SON HOME FROM COLLEGE. COST $75 TO TOW HOME TO UNLOAD THE 2001 F150 5.4 LITER V-8. $75 TO TOW TO FORD OF OCALA, BELLEVIEW, WHO DIAGNOSED BLOWN #3 PLUG, CHARGED $98, THEN $75 TOW TO FORD OF OCALA IN OCALA TOLD $4000 TO REPLACE HEAD OR $6000 TO REPLACE ENGINE. THIS WAS A COMMON OCCURRENCE WITH THIS FAULTY HEAD AND PLUG DESIGN. FORD SHOULD BE MADE TO FIX THIS PROBLEM SINCE REPLACING EITHER THE HEAD OR ENGINE WITH THE SAME FAULTY FORD PRODUCT WAS NOT AN OPTION TO ME. ESTIMATED CHARGES WERE OUTRAGEOUS EVEN FOR A PHYSICIAN TO PAY. PLEASE SEE WWW.F150ONLINE.COM FORUM FOR ADDITIONAL DISGRUNTLED F-150 OWNERS WHOM HAVE HAD SAME PROBLEM. THIS WAS A FRAUD ALERT. *AK

NHTSA ID

10190730

Incident

May 5, 2007

Mileage

113,000 mi

SPARK PLUG # 7 BLEW OUT OF THE FORD F-150 TRUCK WITH A V8 MOTOR. THE PLUG AND COIL STUCK THE FUEL RAIL ABOVE THIS AREA , AND TOOK A CHUNK OF THE FUEL RAIL OUT, ALMOST CRATING A LEAK , VEHICLE COULD CATCH ON FIRE. OVER 100,000 REPORTS ON THE EXACT SAME SPARK PLUG ALONG WITH # 3 PLUG DOING THE SAME THING WITH THE FUEL RAIL ALSO. USUALLY THE OTHER PLUG BLEW A FEW MONTHS AFTER THE FIRST ONE BLEW OUT OF THE ENGINE. REPAIRS WERE TO PULL THE HEADER ,AND DRILL HOLE IN HEADER TO INSTALL A COIL TO REPLACE THREADS TORN ON THE HEAD, AND INSTALL A NEW PLUG DUE TO BLOW OUT AND COIL. *AK

NHTSA ID

10189995

Incident

Apr 16, 2007

Mileage

97,000 mi

ON OCTOBER 27, 2006 I WAS DRIVING MY 2001 FORD F-150 PICKUP DOWN THE HIGHWAY AT ABOUT 45 MILES PER HOUR. ALL OF A SUDDEN WE HEARD A LOUD NOISE AND PULLED OVER. UPON INSPECTION MY HUSBAND NOTICED THAT THE NUMBER 3 SPARK PLUG AND COIL PACK HAD BEEN EJECTED FROM THE CYLINDER HEAD. HE ALSO NOTICED THAT IT HAD CAUSED A SIZEABLE DENT IN THE FUEL INJECTOR RAIL. THE RAIL/FUEL LINE WHICH PROVIDES FUEL UNDER PRESSURE TO THE INJECTORS IS MADE OF STEEL. THE COIL PACK ALTHOUGH THE MOUNTING POINT WAS BROKEN OFF REMAINED PLUGGED IN AND FUNCTIONING. THE SPARK PLUG ALSO REMAINED IN TACT AND APPEARED UNDAMAGED. THE SPARK PLUG STILL RESTING IN THE SPARK PLUG BOOT MANAGED TO FIND A GROUND VERY NEAR IF NOT ON THE DENTED FUEL RAIL. THIS WAS EVIDENT BY THE FACT THAT IT CONTINUED SPARKING AS THE MOTOR SAT AND IDLED AS WE TRIED TO DETERMINE THE SOURCE OF THE PROBLEM. IF THERE HAD BEEN ANY SORT OF FUEL LEAK OR HAD IT RAN LONGER SPARKING AGAINST THE FUEL RAIL, I SUSPECT A FIRE COULD HAVE RESULTED. A RATHER SERIOUS FIRE CONSIDERING THE FUEL IN THE RAIL IS UNDER PRESSURE. ADMITTEDLY THIS MAY BE A VERY UNLIKELY SET OF CIRCUMSTANCES. HOWEVER IN CHECKING ON THE INTERNET THE SPARK PLUG EJECTION SEEM TO BE COMMON AND THE DENTED FUEL RAIL NOT UNCOMMON. THE COIL PACK CONTINUING TO FIRE SEEMS LIKELY AS THE CONNECTION TO THE WIRING HARNESS SEEMS QUITE SECURE. IT ALSO SEEMS THAT THE STEEL FUEL RAIL IS A VERY CONVENIENT GROUND. NOT ONLY DID THIS HAPPEN ONCE NO IT HAPPENED AGAIN ON JANUARY 19, 2007. FORD REFUSES TO RECOGNIZE A PROBLEM WITH THE CYLINDER HEAD AND CHARGES $3000 TO REPLACE THE HEAD AND ALL OF IT INTERNAL COMPONENTS EVERY TIME IT HAPPENS. FORD BLAMES THIS PROBLEM ON THE SPARK PLUG I CAN ASSURE YOU THE SPARK PLUG WAS COMPLETELY IN TACT AND SPARKING NOT IN THE COMBUSTION CHAMBER MIND YOU BUT AGAINST A STEEL FUEL LINE. FORD RECOMMENDS THAT YOU CHANGE THE SPARK PLUGS AT 100,000 MILES MY TRUCK WAS ONLY AT 80,000. *NM

NHTSA ID

10180664

Incident

Oct 27, 2006

Mileage

80,000 mi

2001 FORD EXPEDITION EDDIE BAUER, AT ABOUT 30 MPH, 3RD SPARK PLUG BLEW OUT STRIPPING THREADS AND RUINING COIL. WE REPLACED THE COIL, BUT DEALER WILL NOT RETHREAD, THE DEALER SAYS THAT IF THEY WERE TO RETHREAD IT WOULD NOT HOLD AND WOULD PROBABLY BLOW AGAIN POSSIBLY DOING MORE DAMAGE TO MOTOR. THEY SAID THEY WILL ONLY REPLACE THE HEAD WHICH IS 2000.00. WHEN IT BLEW I WAS ON MY WAY TO THE AIRPORT TO PICK UP FAMILY WITH MY NEWBORN AND FOUR YEAR OLD. I WAS STRANDED ON THE HIGHWAY FOR AN HOUR AND A HALF IN 98 DEGREE HEAT. MY FAMILY WAS STRANDED AT THE AIRPORT FOR TWO HOURS, NOT TO MENTION THE TOW BILL. I CALLED FORD, THEY ACKNOWLEDGE A PROBLEM, BUT TAKE NO RESPONSIBILITY. THEY SAID IT WAS BECAUSE OF POOR MAINTENANCE. BUT MY VEHICLE HAS BEEN 100 PERCENT PROPERLY MAINTAINED. *NM

NHTSA ID

10161269

Incident

Jul 1, 2006

Mileage

217,000 mi

SPARK PLUG BLEW OUT OF THE HEAD ON THE ENGINE. *JB

NHTSA ID

10102684

Incident

Dec 4, 2004

Mileage

19,000 mi

CHECK ENGINE LIGHT CAME ON AT 49000 DIAG REPORTS ERG/BACK FLOW/SOLENOID. REPLACED ALL AND RESET COMPUTER. NEXT DAY LIGHT RETURNED, DIAG REPORTS ERG/BACKFLOW/SOLENOID FAILURE. TELEPHONE TO FORD STATES, SEVERAL HAVE THIS PROBLEM, EXCESSIVE BUILDUP OF CARBON IN EXHAUST MANIFOLD. EXTENDED WARRANTY COVERS REPAIR (DESIGN FLAW). *JB

NHTSA ID

10041236

Incident

Aug 15, 2003

Mileage

49,000 mi