2002 Ford F Super Duty Engine Problems

TRAVELING ON A BUSY HIGHWAY AT 65 MPH; THE SPARK PLUG ON MY 5.4L V8 TRITON BLEW OUT OF ITS SOCKET. (ANY MECHANIC WILL TELL YOU EVERYTHING YOU WANT TO KNOW ABOUT THIS) THIS CAUSED AN IMMEDIATE BANG AND VERY ROUGH RUNNING CONDITION. AS SOON AS IT HAPPENED; THERE WAS AN IMMEDIATE LOSS OF POWER WHICH IN TURN; CAUSED A RAPID REDUCTION IN VEHICLE SPEED. NOT TO MENTION, THE DISTRACTION THAT OCCURRED THAT CAUSED THE LACK OF FOCUS ON SURROUNDING VEHICLES AND OTHER POSSIBLE HAZARDS. THIS IS THE SECOND OCCURRENCE OF A SEPARATE SPARK PLUG BLOWING OUT OF ITS SOCKET ON THE SAME MOTOR. THIS WILL COST SEVERAL THOUSAND IN REPAIRS AFTER ALL IS SAID AND DONE. ON TOP OF THE MONEY SPENT REPAIRING THE LAST INCIDENT. THERE IS A DOCUMENTED HISTORY OF THIS SITUATION WITH THE MORE EXTREME HAVING FIRE ISSUES. THE FIRE IS BECAUSE ATOMIZED FUEL IS SPRAYED INTO THE ENGINE COMPARTMENT DUE TO THERE BEING A HOLE WHERE THE SPARK PLUG IS SUPPOSED TO BE. THERE WAS NO CRASH, FIRE OR INJURY IN THIS CASE. HOWEVER, IT WAS CLOSE TO HAVING ALL THREE. *TR

NHTSA ID

10689548

Incident

Feb 20, 2015

Mileage

88,000 mi

SPARK PLUG EJECTED FROM HEAD, CAME OUT WITH SUCH FORCE AS TO BREAK THE COIL ON THE FUEL RAIL, SHATTER THE SPARK PLUG AND DISINTEGRATED THE SPARK PLUG BOOT. HAD TO TAP LARGER HOLE AND INSTALL THREADED INSERT SO A NEW SPARK PLUG COULD BE THREADED INTO HEAD AND TORQUED TO SPECS. REPLACED THE COIL AND BOOT AND REINSTALL THE FUEL RAIL AND INJECTORS TO MAKE THE TRUCK SERVICEABLE AGAIN. *TR

NHTSA ID

10547162

Incident

Sep 23, 2013

Mileage

171,000 mi

SPARK PLUG IN CYLINDER #2 BLEW OUT OF HEAD TAKING THE THREADS WITH IT. THIS AGAIN HAPPENED 6 DAYS LATER WITH CYLINDER #4. I CHECKED INTERNET AND DISCOVERED THAT THERE HAD BEEN MULTIPLE SITUATIONS WHERE THIS HAS OCCURRED WITH AT LEAST 3 OF FORDS ENGINES. MINE IS THE V10 ENGINE. CALLED THE DEALER I ORDERED THE TRUCK FROM AND THEY INFORMED ME THERE WASN'T A RECALL AND SINCE MY ENGINE WAS OUT OF WARRANTY THEY WOULD NOT BE ABLE TO FIX IT EXCEPT AT MY COST. THEY REFERRED ME TO FORD CUSTOMER SERVICE. THEY TOOK MY INFORMATION BUT SAID THEY WOULD NOT REPAIR IT. ACCORDING TO FORDS TECHNICAL SERVICE BULLETIN TSB 07-21-2 THIS HAS BEEN A PROBLEM AND IF YOUR TRUCK IS UNDER WARRANTY THEY WOULD REPLACE THE HEADS. IF NOT UNDER WARRANTY THEY RECOMMEND HOW TO REPAIR IT AT CUSTOMER COST. THIS IS NOT RIGHT. THE SPARK PLUG BEING BLOWN OUT OF A DEFECTIVE HEAD IS A FIRE HAZARD AND MAJOR PROBLEM. YOU HAVE A HOT CYLINDER WITHOUT ANY FUEL BEING CAPTURED IN AN ENCLOSED AREA. THE PLUG COULD SPARK CAUSING A FIRE WITHIN THE ENGINE COMPARTMENT. FORD SHOULD HAVE TO REPLACE THE HEADS WITH HEADS THAT ARE NOT DEFECTIVE. *TR

NHTSA ID

10507393

Incident

Mar 23, 2013

Mileage

78,000 mi

WENT TO START MY TRUCK AND THAT'S WHEN THE SPARK PLUG BLEW OUT. *TR

NHTSA ID

10456254

Incident

Apr 21, 2012

Mileage

112,000 mi

INJECTOR DRIVE MODULE (IDM), DIESEL 7.3 NAVISTAR ENGINE. IDM FAILED WHERE THE LIKELY CAUSE WAS WATER INFILTRATION OF THE DEVICE WITH SUDDEN CATASTROPHIC RESULTS WHICH INCLUDED A SUDDEN SIGNIFICANT LOSS OF ENGINE POWER, INABILITY TO MAINTAIN HIGHWAY SPEED, INABILITY TO KEEP SPEED ABOVE 5 MILES PER HOUR, AND DEMONSTRATION OF SEVER ROUGHNESS DURING ATTEMPTS TO REV THE ENGINE OR IDLE LOADS. DUE TO THE IDM FAILURE, THREE OF EIGHT FUEL INJECTORS WERE RENDERED NONFUNCTIONAL AND REPLACED; ALSO THE ACTUAL NUMBER OF INJECTORS THAT WERE ONLINE OR OFFLINE DURING THE IDM FAILURE TO ENGINE SHUT-DOWN PERIOD WAS UNKNOWN. DURING THE IDM FAILURE TO ENGINE SHUT-DOWN PERIOD OF ~3 MILES, THE VEHICLE'S OBDII SYSTEM DID NOT ILLUMINATE ANY DASHBOARD INDICATORS DESPITE THE ENGINE'S INABILITY TO FUNCTION NORMALLY. IDM WAS OPERATED IN MANUFACTURER'S OEM CONFIGURATION, WITHOUT MODIFICATIONS, AND UNDER NORMAL CONDITIONS. ALL PARTS SENT DIRECTLY FROM MECHANIC SHOP TO SUPPLIERS UNDER CORE REPLACEMENT REQUIREMENTS. SUBSEQUENT RESEARCH ON VEHICLE OWNER'S FORMS AND CONVERSATION WITH MECHANIC SHOW FAILURE OF THE IDM DUE TO WATER PENETRATION / INFILTRATION IS KNOWN AND RANGES IN INDICATIONS FROM MINE (SUDDEN SEVER POWER LOSS) TO COMPLETE POWER LOSS / ENGINE STOP. *TR

NHTSA ID

10444842

Incident

Dec 24, 2011

Mileage

74,000 mi

SPARK PLUG BLOWOUT. *TR

NHTSA ID

10429127

Incident

Oct 7, 2011

Mileage

83,000 mi

THE #9 SPARK PLUG SHOT OUT 9000 MILES AFTER THE FORD DEALERSHIP REPLACED ALL 10 PLUGS FOR $270. I WAS TOLD BY ALL PRIVATE GARAGES AND MECHANICS LOCALLY THAT THE FORD DEALERSHIP HAD TO REPLACE THE PLUGS OTHERWISE THEY WOULD SHOOT OUT. (GLAD I USED THE FORD DEALERSHIP) WHEN I CONTACTED THE FORD DEALERSHIP ABOUT THE FAILURE, THEY TOLD ME THAT THEY WOULD HAVE IT TOWED IN AND BE ABLE TO FIX IT FOR AROUND $350.00. WHEN I EXPLAINED TO THEM THAT I THOUGHT THEY SHOULD GUARANTEE THEIR WORK AND FIX IT FOR FREE, I THINK I MADE THEM LAUGH. IF AND WHEN I GET THIS TRUCK FIXED AND SOLD, I WILL NEVER EVER BY A FORD PRODUCT AGAIN. *TR

NHTSA ID

10424758

Incident

Aug 27, 2011

Mileage

105,000 mi

THROWN SPARK PLUG FROM 2002 F-250. *TR

NHTSA ID

10317466

Incident

Mar 27, 2007

Mileage

80,000 mi

I HAVE A 2002 FORD F250 THAT IN THE LAST YEAR HAS BLOWN OUT THE SPARKPLUGS 3 DIFFERENT TIMES. I HAVE BOUGHT THE REPLACEMENT KIT FOR IT EACH TIME AND I AM STILL HAVING THE PROBLEM. *TR

NHTSA ID

10294473

Incident

Dec 1, 2009

Mileage

52,000 mi

ORIGINAL SPARK PLUG WAS EJECTED FROM THE ENGINE THREAD ON THE HEAD WAS DESTROYED. DEALER SAID IT IS A KNOWN ISSUE, BUT THERE IS NO RECALL ISSUED. WELL, THERE SHOULD BE ONE !!! *TR

NHTSA ID

10226862

Incident

May 6, 2008

Mileage

87,500 mi

2002 F250 BLOWING OUT SPARK PLUGS. *TR

NHTSA ID

10215119

Incident

Sep 9, 2007

Mileage

100,000 mi

2002 FORD F-250 5.4L MOTOR. BLEW SPARK PLUG ON DRIVERS SIDE 2ND ONE FROM FRONT OUT OF VEHICLE. *NM

NHTSA ID

10137509

Incident

Sep 17, 2005

Mileage

81,000 mi

2002 FORD F250 SUPERDUTY V10- ENGINE. DRIVING TO WORK AT ABOUT 15 MPH. HEARD A LOUD BANG FROM ENGINE COMPARTMENT, ENGINE STARTED TO IDLE ROUGH, EXHAUST SMELL AND LOUD POPPING NOISE FROM ENGINE, TOWED TO DEALER WAYSIDE FORD MARLBORUGH MA., VERIFIED SPARK PLUG BLOWN OUT OF HEAD. TRUCK HAS BEEN DEALER MAINTAINED. CURRENTLY HAS ABOUT $70K MILES. PLUGS ARE NOT SCHEDULED TO BE CHANGED UNTIL 100K MILES. TRUCK IS NOT DRIVALBE, ESTIMATE ABOUT $300.00 TO REPLCE HEAD AND COIL. WAITING FOR RESPONSE FROM FORD FOR HELP. THIS IS A COMMOM PROBLEM PER DEALER AND OWNERS GROUPS.*AK

NHTSA ID

10104166

Incident

Dec 20, 2004

Mileage

70,000 mi