Valve Cover Leak

[GMAN]

The other day I was at my local Sonic to grab some lunch. I turnd off the engine, and enjoyed my burger and fries. When I stared up to leave, I heard a loud "POP". I didn't think much of it at the time, but then I noticed that that my exhaust flow wasn't smooth. Like I can tell it was missing. So I took of the spark plug plate, and my spark plugs were full of oil! To make things worse, spark plug #7 was blown out of the hole, and the coil was obliterated. So now I have to do valve cover gaskets and new COP's

 

[Aquabrit]

Spark plug blew out the hole?

Did it just come loose or have the threads in the head stripped? (i read its a common thing on B heads)

 

[vr4]

not only do you have to do the gaskets and coils but you have to put an insert into the hole for a new plug too.

 

[GMAN]

not only do you have to do the gaskets and coils but you have to put an insert into the hole for a new plug too.

What do you mean by an insert? Do I have to tap for new threads?

 

[vr4]

http://www.sjdiscounttools.com/mtn9200.html

Designed to aid in repairing Ford modular cylinder heads. A quality fool proof repair system that is fast, cost effective, and simple to use. Used to repair damaged threads from blown or deteriorated spark plugs in 4.6L, 5.4L, and Ford V10 Triton engines.

just 1 of the many kits out there for this common problem.

 

[Sal329]

I had 2 spark plugs blow out of mine. One blew out, fixed it and on the test drive another one went.

 

[BAD97LSC]

i cant believe how much oil in down in the journals. when i took the covers off my 98 to powder coat them, i bought a gasket set from felpro, comes with the new valve cover gaskets and spark plug tower oil seals as wel, thats what you need, thats why oil is filling up the journals. as far as the plug goes, either have a pro instal a helicoil or replace the head. that sucks bad.

 

[ford nut]

I had 2 spark plugs blow out of mine. One blew out, fixed it and on the test drive another one went.

OMG I think I would have sold the car when I was done.

GMAN that tool for doing the job is spendy get some quotes on how much at some shops you trust, a good wrench who has done it before will give you a good price.
Its a known problem v 10s spit them out like chewing gum.
It is the main reason I wont buy a pre 2003 ford truck.

 

[vr4]

OMG I think I would have sold the car when I was done.

GMAN that tool for doing the job is spendy get some quotes on how much at some shops you trust, a good wrench who has done it before will give you a good price.
Its a known problem v 10s spit them out like chewing gum.
It is the main reason I wont buy a pre 2003 ford truck.

you could always buy a 3v and have the plugs break upon removal

 

[ford nut]

you could always buy a 3v and have the plugs break upon removal

LOL whats up with that ?
Havent heard that one yet....I guess not too many 3v in for a tune up yet.
I wonder about Ford and some of the junk they have been making.:shifty:
I have a 96 bronco I dont see me getting past that year.

 

[vr4]

heres a generic picture of the new spark plug....

heres how they typically look when they break...

ive been lucky in that of the 36 that ive removed so far ive only broken 1 and the porcelain didnt break off in the shell so it was an easy removal.

what happens is the shell and most often the porcelain will break off in the head and must be removed with a tap and threaded puller. if you screw up it could mean new cyl head time.

 

[Aquabrit]

I wonder about Ford and some of the junk they have been making.:shifty:

Me too! For a company thats been making cars for 100 and odd years, they don't seem to have a clue?

Anyway, i was just curious, if you were to thread insert a spark plug hole, would that plug not dissipate heat as well? Would it be a good idea to run a step colder plug for a repaired hole? (im asking now, as its only a matter of time before something like this happens to more of us)

 

[vr4]

Me too! For a company thats been making cars for 100 and odd years, they don't seem to have a clue?

Anyway, i was just curious, if you were to thread insert a spark plug hole, would that plug not dissipate heat as well? Would it be a good idea to run a step colder plug for a repaired hole? (im asking now, as its only a matter of time before something like this happens to more of us)

fords official stance is to not install an insert of any kind. weve done 100s at the shop with no issues and using the standard heat range plug for the vehicle.

granted these are normal trucks not driven hard.

 

[ford nut]

Me too! For a company thats been making cars for 100 and odd years, they don't seem to have a clue?

Anyway, i was just curious, if you were to thread insert a spark plug hole, would that plug not dissipate heat as well? Would it be a good idea to run a step colder plug for a repaired hole? (im asking now, as its only a matter of time before something like this happens to more of us)

It doesnt happen very often on the 4v.
The 2v on the other hand it happens all the time.
From what I was told hole # 3 has only 3 threads holding in the plug it was fixed in 2003.
I think part of the problem in the 4v is how deep the plug is in the head, if you are not careful you can cross thread the plug.
But your right you would think a car company that has been around 100 years would know how many threads are needed to hold in a spark plug.

ive been lucky in that of the 36 that ive removed so far ive only broken 1 and the porcelain didnt break off in the shell so it was an easy removal.

what happens is the shell and most often the porcelain will break off in the head and must be removed with a tap and threaded puller. if you screw up it could mean new cyl head time.

Wow that sucks....no 3v for me !
Hopefully Ford comes clean on this one and finds a fix.

 

[vr4]

It doesnt happen very often on the 4v.
The 2v on the other hand it happens all the time.
From what I was told hole # 3 has only 3 threads holding in the plug it was fixed in 2003.
I think part of the problem in the 4v is how deep the plug is in the head, if you are not careful you can cross thread the plug.
But your right you would think a car company that has been around 100 years would know how many threads are needed to hold in a spark plug.


Wow that sucks....no 3v for me !
Hopefully Ford comes clean on this one and finds a fix.

word has it the hole that the shell goes thru is larger on 06+ engines but i cant confirm his yet.


the problem is less noticed on the 4V due to the plugs being easy to get to. 3 and 4 on the trucks are a PITA so these are the most common to blow out.

 

[GMAN]

Spent the day working on the valve covers, replacing the gaskets, coils and COP's. I have to tell you, I am not a certified mechanic by no means. I will try everything I believe I can handle at least once. Today I tried the valve cover gaskets. This was a royal PITA! I finally got the passenger side off, no damage was done on that side. Everything looked in tact.

I got the cover back on and buttoned it back up and moved to the drivers side. First I moved the master cylinder, then the fuse box, and move the power steering fluid up. I am having a real hard time getting this valve cover off. I really need some help with this one. Anyone have any ideas?

 

[XLRVIII]

That explains why you didn't answer your phone...(lol)

was gonna give you some moral support and some pointers on putting a thread insert in if you do indeed need to go that route.

my 95 blew a plug out, I put a steel insert in that lasted well over 200K hard milesh..
"do not fear the insert, it's not as bad as it sounds".

Tip for the valve cover, try and see if you can jack the motor up a bit, you hopefully have a little "slop" in the mount and it'll let the motor up a 1/2 inch or so.
Give it a shot...and feel free to give me a call if I can help in any way.

 

[GMAN]

I didn't know you called. I was getting so frustrated, I had to walk away.

 

[chicken]

heres a generic picture of the new spark plug....

heres how they typically look when they break...

ive been lucky in that of the 36 that ive removed so far ive only broken 1 and the porcelain didnt break off in the shell so it was an easy removal.

what happens is the shell and most often the porcelain will break off in the head and must be removed with a tap and threaded puller. if you screw up it could mean new cyl head time.

at least fords removal kit is fairlly easy, stick vac cap into bottom, thread metal sleeve, insert tool and pull out, ive done a couple, only had a prob with one, where another shop tried to use a 5/8 plug socket and rounded the nut, of course it was cyl #4, so that was fun

 

[GMAN]

My plugs didn look like that. They all came out, all threads were in tact. The one plug in in question, the gap closed up on it. I believe it somehow backed its way out.

 

[chicken]

best bet, is to see if the threads are still in tact, try carefully to install another of the plugs from another hole and dont over tighten, i have personally never seen one come out and the threads be ok

 

[ford nut]

best bet, is to see if the threads are still in tact, try carefully to install another of the plugs from another hole and dont over tighten, i have personally never seen one come out and the threads be ok

+1 the pop you heard was the plug poping out it would have to do some damage if your lucky it was loose and only ripped out a few threads.
It was a little missle thats what took out your cop

 

[Sal329]

When my plug popped out the threads looked perfect. I tried another brand spark plug and it wouldn't thread in. I retreied the one I pulled out and it threaded in fine. I even drove the car 30 miles from work to home and the next mornin started the car and plug blew back out.

 

[GMAN]

Well, I am at a stopping point. I got the valve cover off, and the spark plug turned freely in cylinder#7. I am going to have to get it fixed. I am apprehensive about doing that myself. And to think, I was getting ready to sell it. Is this the Marks way of saying "You're not selling me!!"? I guess I can either dump more money into her now. No use in selling her at this point. So I have a few options here. Fix the spark plug hole, or go with different heads. I was thinking about cobra heads. I hope they don't have this know problem. What would be the ideal heads to go with?

 

[vr4]

youll pick up a little power going with newer heads but it wont be worth the cost involved if a shop can install an insert without pulling the heads. youll also need to buy a new intake manifold and tube to go with the new heads unless you find a 99 continental


best bet would be to call around to a few FLM dealers and ask if they have any experience installing inserts for blown out plugs. we do 2-3/week