2002 FORD F-150 Engine Problems

The contact owns a 2002 Ford F-150. The contact stated while driving at an undisclosed speed, the vehicle made a loud sound. No warning light was illuminated. The vehicle was towed to an independent mechanic, who diagnosed and determined that cylinder #3 spark plug had blown out, but no repair was recommended at the time. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 108,000.

Mileage: 108,000

The contact owns a 2002 Ford F-150. The contact stated that she observed smoke emanating from under the vehicle near the engine compartment. The contact stated that she opened the hood and flames erupted from the engine compartment near the battery. The contact threw dirt on the engine to extinguish the fire. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and a complaint was filed. The failure mileage was approximately 200,000.

Mileage: 200,000

1. Coils on top of spark plug get moisture in them when there is just the right kind of rain storm. This makes the coil or coils fail until the dry out. This seems to make the coil eventually go bad. Yes, it is available for inspection. 2. Not sure if its a combination of heat and moisture but sometime right away and sometimes a few minutes into driving the coil or coils fail and the engine loses power. Then if seems to be a random, unpredictable occurrence until it dries out, Very Unsafe. If one coil fails it loses just a little power, but if more than one fails it loses a lot of power and stalls at times. This is why I am writing it up. A few time now, I have gone to pull into traffic and then I lose power and either have to run off the road or just upset the car behind me if they are not too close. 3 & 4. I have advise all the Ford dealerships in my area trying to find one that has a fix yet. The only fix Ford has, is a new designed coil, which does not appear to be any better. The dealership just replaces the coil. I have had all my coils replaced, some 2 or 3 times. 5. It depends, sometime the engine light will come on and advise which coil is misfiring and sometimes if does not. Right now my engine light is on and it displays the #6 coil misfire. Then the engine light will go out after it dries out and stops failing or it will stay off if the coil had gone bad again. I am sure its not just the F 150, but the 4.6 liter engine that is in other vehicles. I started keeping track in 2012. I wrote a letter to Ford in 2015 and they replied, there was no recall. I have several repair receipts and the letter from Ford if you need that. Just search on your site and you will see many complaints. One example Manufacturer Communication number: 041601. If you google "ford fix for moisture in coils" you will see many forums trying to figure out a fix and just complaining.

SPARK PLUG SHOOTS OUT OF MOTOR WHILE DRIVING. HAS BEEN REPORTED ON LOTS OF VEHICLES FOR YEARS.

Mileage: 350,234

THIS IS FOLLOW UP ASSESSMENT TO MY 9/22/2019 CLAIM [XXX]- WHERE I FOUND MYSELF IN A VERY DANGEROUS VEHICLE RUN AWAY SITUATION THAT RESULTED IN A REAR END ACCIDENT WITH ANOTHER VEHICLE. MY MECHANIC'S FIRST OBSERVATION WHEN TURN IGNITION KEY, THE ENGINE RACED AT FULL THROTTLE OUT OF CONTROL. AFTER QUICKLY SHUTTING DOWN ENGINE THE SYMPTOMS LEAD MY MECHANIC TO TEST THE IDLE AIR CONTROL VALVE. HAVING NEVER SEEN THIS DANGEROUS SYMPTOM FROM A BAD IACV, HE CONTINUED TO DO FURTHER TEST ON THE IACV ONLY TO DETERMINE THE PART WAS INDEED DEFECTIVE. AFTER DIAGNOSING THE PROBLEM, THE DEFECTIVE IACV PART WAS QUICKLY REPLACED. THE ENGINE IS NOW RUNNING GOOD AGAIN. IF YOU NEED TO CONTACT MY MECHANIC: DUGAN AUTO SERVICE, NARVON PA - DOUG MILLER 464-798-8097 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TT

Mileage: 139,400

THE TRUCK SIMPLY SHUT DOWN WHILE I WAS DRIVING. THE ENGINE STOPPED RUNNING. FOR A PERIOD OF ABOUT A MONTH PRIOR TO THIS ACTION, THE TRUCK WOULD SOMETIMES, RANDOMLY, NOT START. AFTER WAITING A PERIOD OF TIME THE TRUCK WOULD START.

Mileage: 150,000

TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE DRIVING VARIOUS SPEEDS, THE CONTACT HEARD A LOUD ABNORMAL NOISE UNDERNEATH THE HOOD AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED BY A DEALER. THE CONTACT KNEW THAT THE FAILURE WAS CAUSED BY A SPARK PLUG. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 190,000. *BF *JB

Mileage: 190,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT AN EXPLOSION OCCURRED UNDER THE HOOD AND THE VEHICLE CAUGHT FIRE WHILE PARKED IN THE DRIVEWAY. THE FIRE WAS EXTINGUISHED BY THE FIRE DEPARTMENT. THE VEHICLE ONLY HAD LIABILITY COVERAGE; THEREFORE, THE FAILURE WAS NOT COVERED BY THE INSURANCE COMPANY. THE VEHICLE WAS TAKEN TO METRO FORD INC (2860 S NOLAND RD, INDEPENDENCE, MO 64055, (816) 254-9800), BUT THEY COULD NOT ASSIST. THE DEALER SUGGESTED HAVING AN INDEPENDENT MECHANIC DIAGNOSE THE VEHICLE. THE MANUFACTURER WAS NOT CONTACTED. THE CONTACT STATED THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V017000 (VEHICLE SPEED CONTROL), WHICH COULD HAVE CAUSED THE FIRE. THE FAILURE MILEAGE WAS 204,000. *BF *TR

Mileage: 204,000

TL* THE CONTACT OWNED A 2002 FORD F-150. AFTER THE CONTACT TURNED OFF AND EXITED THE VEHICLE, HE WAS ALERTED BY A PASSERBY THAT THERE WERE FLAMES UNDER THE HOOD. THE FLAMES WERE NEAR THE DRIVER'S SIDE OF THE ENGINE COMPARTMENT NEAR THE BRAKE SYSTEM. A FIRE INSPECTOR EXTINGUISHED THE FLAMES. THE VEHICLE WAS DESTROYED BY THE FIRE. A DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS UNCERTAIN IF THE FAILURE WAS RELATED TO NHTSA ACTION NUMBERS: EA05005 (ELECTRICAL SYSTEM, VEHICLE SPEED CONTROL) AND DP05005 (ENGINE AND ENGINE COOLING) AND NHTSA CAMPAIGN NUMBERS: 06E056000 (FUEL SYSTEM, GASOLINE) AND 05V388000 (VEHICLE SPEED CONTROL). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE REMAINED AT THE SCENE. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 175,000.

Mileage: 175,000

SPARK BLOW BLOW FROM THE HEAD NO. 6 I THE MECHANIC FIX IT AND THAT HAPPENED YESTERDAY I CANNOT REMEMBER THE HOPPING IN VEGAS I CAN REMEMBER ' THE

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT THE SPARK PLUG EJECTED OUT OF THE ENGINE COMPARTMENT WHILE DRIVING APPROXIMATELY 65 MPH. THE VEHICLE WAS TOWED FROM THE CONTACT'S RESIDENCE. MCMAGHN FORD DIAGNOSED THAT THE ENGINE WOULD NEED TO HAVE A NEW CYLINDER HEAD. THE MANUFACTURER WAS NOTIFIED, BUT DID NOT OFFER FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS 120,000.

Mileage: 120,000

TAKATA RECALL MY SPARK PLUG BLOW OUT ON # 6 HEADER TODAY ON 3/23/2017 ON MY WAY TO WORK AT 4:00 AM ON ROUT 390 IN PA

Mileage: 210,000

BLEW SPARK PLUG OUT OF HEAD.

Mileage: 155,000

VEHICLE IN MOTION, CITY STREET, SPEED AT 35MPH. SUDDEN LOUD BANG, ENGINE STARTED BANGING. SPARK PLUG #4 BLEW OUT OF ENGINE HEAD.

Mileage: 73,000

STARTED VEHICLE AND HEARD A REAL LOUD BANG FOLLOWED BY A LOAD CONTINUOUS POPPING SOUND. A SPARK PLUG GOT BLOWN OUT OF THE ENGINE AND IT TOOK THE COP WITH IT SO A FIRE COULD NOT START. WE WERE STRANDED IN BAD WEATHER.

Mileage: 124,729

#3SPARK PLUG BLEW OUT OF RIGHT CYLINDER HEAD . SINCE THE INJECTOR WAS STILL PUMPING FUEL INTO THE OPEN CHAMBER THIS COULD HAVE CAUSED AN ENGINE FIRE INOW HAVE FOUND THIS TO BE SOMEWHAT OF A PROBLEM WITH THE 4.6 LITRE ENGINE DUE TO THE ALUMINUM HEADS.

Mileage: 190,000

THE SPARK PLUG ON THE PASSENGER SIDE OF MY VEHICLE EXPLODED OUT OF THE HEAD AS SOON AS I STARTED THE VEHICLE BREAKING THE COIL PACK IN THE PROCESS. I PURCHASED THE VEHICLE USED A YEAR AGO AND SINCE THE PLUG BLEW OUT ON ME I DISCOVERED THAT THIS IS NOT THE FIRST TIME THIS HAS HAPPENED TO MY TRUCK SO IT IS AN ONGOING PROBLEM.

Mileage: 159,000

WHILE PULLING UP TO A STOP LIGHT MY TRUCK STARTED POPPING AND SHAKING. I PULLED OVER AND OPENED THE HOOD TO FIND OUT A SPARK PLUG HAD BLOWN OUT OF THE MOTOR. IT EXPLODED WITH SUCH FORCE IT BROKE THE COIL OVER HOUSING ON THE HEAD. I HAVE CALLED FORD AND THEY SAY THEY DON'T KNOW OF ANY ISSUES OF THIS. IT IS ALL OVER THE INTERNET ABOUT IT. THEY ARE IN COURT RIGHT NOW OVER THE 2005 AND UP VEHICLES HAVING THE SAME ISSUE. I AM THE ORIGINAL OWNER AND HAVE NEVER HAD TO REPLACE THE PLUGS SO THEY ARE STRAIGHT FROM THE FACTORY, AND THE TRUCK HAS ONLY 123,000 MILES ON IT. IT IS NOW GOING TO COST ME OVER $400.00 TO FIX THIS ONE PLUG WITH NO GUARANTEE IT WON'T HAPPEN TO ANY OTHER PLUGS. I'M RETIRED ON SOCIAL SECURITY AND CANNOT AFFORD A NEW TRUCK PAYMENT, OR CONTINUE TO FIX THEIR DEFECTS.

Mileage: 123,000

VEHICLE CAUGHT FIRE AFTER BEING PARKED FOR 5 HOURS. ALMOST BURNT MY BUILDING DOWN.

ABOUT 6MONTHS AGO, CRUISING ABOUT 60MPH; HEARD A "POP", LOST ENGINE POWER, ENGINE LIGHT ON,...PULLED OVER AND DISCOVERED #3 CYLINDER MISSING THE SPARK PLUG AND THE COP BROKEN. HAD IT TOWED HOME (APPROX 25MILES); WENT ONLINE AND DISCOVERED IT'S A SYSTEMIC PROBLEM WITH MANY OTHER FORD V8-V10 1997-2003 MOTORS.

Mileage: 139,000

SPARK PLUG EJECTED OUT OF MOTOR WHEN I WAS PULLING OUT OF A DRIVEWAY ONTO A CITY STREET.

Mileage: 92,364

I BLEW THE 3RD CYLINDER SPARK PLUG OUT ON THE PASSENGER SIDE, 2 TIMES IN 600 MILES WHILE DRIVING AT NORMAL HIGHWAY SPEEDS. THIS CAUSED RAW FUEL TO LEAK ONTO THE HOT MANIFOLD CAUSING A SAFETY ISSUE. I SPENT 1142.17 TO HAVE THIS ISSUE REPAIRED.

Mileage: 96,212

SPARK PLUG WAS EJECTED OUT OF THE ENGINE.

Mileage: 120,000

SPARK PLUG EJECTED FROM ENGINE.

Mileage: 120,000

EXHAUST MANIFOLDS HAVE DEVELOPED HOLES IN THEM. I BELIEVE FORD'S SUPPLIERS PROVIDED INFERIOR MATERIALS IN THEIR CASTING OF THE MANIFOLDS. THIS NOT ONLY OFFERS MORE POLLUTION TO THE ATMOSPHERE BUT IS A POSSIBLE FIRE HAZARD. MY VEHICLE HAS BEEN WELL CARED FOR AND HAS ONLY 37000 ORIGINAL MILES. I HAVE VEHICLES BUILT IN THE 1950 AND THEIR EXHAUST MANIFOLDS CONTINUE TO FUNCTION. I BELIEVE A RECALL ON THESE VEHICLES IS IN ORDER AND FORD MOTOR COMPANY SHOULD MAKE THE NECESSARY REPAIRS AT THEIR EXPENSE. UPDATED 10/01/15*LJ *CN

Mileage: 37,000

DRIVING HOME FROM THE RIVER TOWING MY BOAT A SPARK PLUG BLEW OUT OF THE ENGINE WITH NO WARNING LEAVING ME STRANDED IN THE MIDDLE OF THE DESERT.

Mileage: 97,000

WAS DRIVING MY VEHICLE AND THE SPARK PLUG WAS BLOWN OUT OF THE ENGINE. COULD HAVE CAUGHT ON FIRE. NEVER HEARD OF THIS HAPPING BEFORE UNTIL THE TOW TRUCK DRIVER TOLD ME HIS EXPEDITION WITH A TRITONV8 DID THE SAME THING. DEALER WANTED $700 TO FIX THE SPARK PLUG AND $1200 TOTAL TO REPLACE ALL COIL PACKS AND PLUGS WHICH IS RIDICULOUS FOR A NON-CUSTOM PICK UP TRUCK. WHAT IF MY WIFE WOULD HAVE BEEN DRIVING AND NOT KNOWN WHAT TO DO? IT COULD HAVE CAUGHT FIRE OR CAUSED A CRASH. THE DEALER RATTLED OFF THE ESTIMATE LIKE THEY DO IT ALL THE TIME WHICH TELLS ME THIS IS A DEFECT IN MANUFACTURING AND WHY HAS THIS NOT BEEN RECALLED?

Mileage: 122,000

TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE DRIVING AT 5 MPH, THE ENGINE STALLED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 140,000. UPDATED 5/20/15*CN UPDATED 10/05/2017*CN

Mileage: 140,000

WHILE DRIVING AT 15 MPH CYLINDER #5 SPARK PLUG LIBERATED IT SELF FROM THE ENGINE. *TR

Mileage: 138,000

THE SPARK PLUGS WERE BLOWN OUT OF THE HEADS; THE THREADED PORTION OF THE HEAD WAS STRIPPED; HELI COILS WERE USED TO CORRECT THE PROBLEM; THIS HAPPENED THREE TIMES NOW IN LESS THAN A MONTH. *TR

Mileage: 151,020

TL*THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE CONTACT NOTICED SMOKE AND AN OIL ODOR EMITTING FROM THE FRONT OF THE VEHICLE. UPON FURTHER INSPECTION, THE CONTACT NOTICED THAT OIL WAS LEAKING FROM THE EXHAUST. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 140,000.

Mileage: 140,000

TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE THE VEHICLE WAS PARKED, SMOKE APPEARED UNDER THE HOOD AND THE VEHICLE CAUGHT FIRE. A POLICE REPORT WAS FILED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 107,000.

Mileage: 107,000

SPARK PLUG BLEW OUT OF HEAD. *TR

Mileage: 134,600

2002 F150 HARLEY DAVIDSON EDITION WITH ONLY 75,000 MILES BLEW A SPARK PLUG OUT OF THE HEAD. FORD ADMITS NO CULPABILITY EVEN THOUGH THEY HAVE TSB'S. ESTIMATE TO REPAIR PLUG & CHANGE OUT OTHER 7 SPARK PLUGS WITH 8 NEW COILS WAS $2800. I COULD ALMOST PURCHASE A NEW ENGINE FOR THAT. FOUND A REPUTABLE GARAGE TO DO THE WORK FOR AROUND $900 TOTAL. UNDERSTAND THAT I SHOULD GET USED TO THIS HAPPENING UNTIL ALL 8 SPARK PLUG HOLES HAVE BEEN REPAIRED. FORD MAN FOR 35 YEARS. OWN 3 CURRENTLY. IF DEPENDABILITY IS NO LONGER A PRIORITY FOR FORD DON'T KNOW WHAT I WILL DO. *TR

Mileage: 75,000

SPARK PLUG BLEW OUT OF #2 CYLINDER TAKING THREADS WITH IT REQUIRED SPECIAL INSERT FOR NEW PLUG COST $400 POSSIBLE FIRE HAZARD AS FUEL BLOWS INTO ENGINE COMPARTMENT AND SPARK PLUG IS STILL FIRING. *TR

Mileage: 150,000

ANOTHER SPARK PLUG BLEW OUT OF CYLINDER HEAD TAKING THREADS WITH IT. POSSIBLE FIRE HAZARD AS FUEL SPEWS INTO ENGINE COMPARTMENT WITH LIVE SPARKS CLOSE BY. *TR

Mileage: 160,000

WHILE DRIVING MY VEHICLE UNDER VERY NORMAL CIRCUMSTANCES, TRAVELING APPROXIMATELY 30MPH, MY TRUCK BEGAN TO RUN VERY ROUGH AND THERE WERE LOUD POPPING NOISES COMING FROM THE TOP OF THE PASSENGER SIDE VALVE COVER. IT TURNED OUT TO BE A BLOWN-OUT SPARK PLUG AND COIL PACK. *TR

Mileage: 160,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT THE SPARK PLUGS DETACHED FROM THE CYLINDER HEAD AND CAUSED THE VEHICLE NOT TO PERFORM PROPERLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 200,006.

Mileage: 200,006

ENGINE QUITS RUNNING AND WONT RESTART, SO YOU HAVE NO POWER STEERING OR BRAKES. PROBLEM INDICATORS ARE 1. ENGINE WONT RESTART/ OR QUIT RUNNING 2. ODOMETER READS ALL DASHES, NO NUMBERS,3. ANTI THEFT ACTIVATED. THIS IS CAUSED BY THE POWER WIRE IN THE FUSE BOX UNDER THE HOOD CORRODING OFF FOR THE PCM RELAY AND LEAVING THE PCM DEAD. *TR

Mileage: 168,000

ON MARCH 22, 2014, THE TRUCK WAS PARKED IN A LOCAL PARKING LOT, THE IGNITION KEY WAS REMOVED AND THE TRUCK WAS LOCKED. THE DRIVER RETURNED TO THE TRUCK TO FIND THAT WHILE IT WAS PARKED, A FIRE HAD BEGUN IN THE ENGINE COMPARTMENT OF THE TRUCK, AND THE FIRE DEPARTMENT AND POLICE DEPARTMENT WERE ON THE SCENE PUTTING OUT THE FIRE. BECAUSE OF THE QUICK ACTIONS OF AN INDIVIDUAL PARKED NEARBY WHO USED A FIRE HOSE TO CONTAIN THE FIRE UNTIL THE FIRE DEPARTMENT ARRIVED, THE CABIN AND THE BODY OF THE TRUCK WERE SPARED, AND THE DAMAGE WAS LOCALIZED TO THE ENGINE COMPARTMENT. THE CAUSE OF THE FIRE WAS THE SPEED CONTROL DEACTIVATION SWITCH.

Mileage: 204,000

SPARK PLUG BLEW ON MY F150 KING RANCH. *TR

Mileage: 125,000

ON MORE THAN ONE OCCASION SPARK PLUG AND COIL FOR #4 CYLINDER HAS BLOWN OUT. FEW TIMES I WAS ABLE TO TIGHTEN DOWN THE PLUG AND REPLACE THE COIL. LAST TIME IT HAPPENED IT MESSED UP THE THREADS. HAD TO BUY A SPECIAL PLUG TO PUT IN ALONG WITH A RETHREAD PART. NOW I CAN NOT EVERY REPLACE THAT SPARK PLUG DO TO HAVING THE THREADING HOUSING. *TR

Mileage: 145,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING 65-75 MPH, THE ENGINE WOULD HESITATE THEN SURGE FORWARD WHEN THE CONTACT WAS ATTEMPTING TO ACCELERATE. THE FAILURE WAS RECURRING. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC, WHO STATED THAT THE EGR SENSOR WOULD NEED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURE WAS NOT ALERTED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 58,730. THE VIN WAS NOT AVAILABLE. . ..UPDATED 03-12-14 *BF

Mileage: 58,730

ENGINE THREW A SPARK PLUG OUT OF THE HOLE, BROKE THE MOUNT FOR THE COIL PACK. THIS IS THE THIRD TIME I HAVE HAD THIS ISSUE. *TR

Mileage: 134,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, THE VEHICLE MADE A LOUD NOISE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THERE WAS A BLOWN SPARK PLUG THAT NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND CURRENT MILEAGE WAS 170,000.

Mileage: 170,000

#4 SPARK PLUG BLEW OUT OF THE ENGINE. STRIPPING THE THREADS FROM THE BLOCK. *TR

Mileage: 170,000

I WAS DRIVING ABOUT 60 MPH ON A COUNTY ROAD WHEN THE NUMBER 3 SPARK PLUG BLEW OUT OF THE CYLINDER HEAD. I WAS ABLE TO STOP SAFELY, BUT THE INCIDENT SCARED MY 5 YEAR OLD DAUGHTER. BECAUSE OF THE PLUG BLOWING OUT ME AND MY DAUGHTER WERE STUCK ON THE SIDE OF THE ROAD FOR ABOUT AN HOUR IN THE FLORIDA SUN WAITING ON SOMEONE TO COME AND GET US AND THE TRUCK. I CALLED AROUND AND SEVERAL REPAIR SHOPS STATED IT WOULD COST ME BETWEEN $700 AND A $1000. AFTER DOING EXTENSIVE RESEARCH ONLINE I DISCOVERED THIS IS A MAJOR PROBLEM FOR THE 5.4 TRITON ENGINE. I CALLED FORD AND THEY SAID THE REPAIR COST WOULD BE ON ME TO FIX. I FEEL THAT THERE NEEDS TO BE A RECALL BECAUSE OF THIS DEFECT IN THE CYLINDER HEAD. *TR

Mileage: 252,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT HE HEARD A LOUD BANGING NOISE COMING FROM UNDER THE HOOD. UPON INSPECTION, THE CONTACT DISCOVERED THAT THE SPARK PLUG HAD BECOME LOOSE AND HAD EJECTED FROM THE CYLINDER HEAD. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 106,800. ...UPDATED 11-12-13 *BF ACCORDING TO THE INVOICE, THE #2 SPARK PLUG BLEW OUT OF THE HEAD. THE VEHICLE WAS REPAIRED. UPDATED 11/19/13

Mileage: 106,800

AFTER STARTING ENGINE, SPARK PLUG #2 BLEW OUT OF CYLINDER HEAD. DAMAGING COIL WITH A LOAD EXPLOSION! *TR

Mileage: 64,000

SPARK PLUG EJECTION WHEN ACCELERATING FROM A STOP. THIS IS THE 3RD (THIRD) PLUG THAT HAS BLOWN OUT IN THE PAST YEAR. THIS IS THE FOURTH REPAIR DUE TO THE FIRST REPAIR USING A "REPAIR KIT" THAT THE LOCAL DEALERSHIP RECOMMENDED TO THE MECHANIC. THIS REPAIR KIT AND COIL PACK BECAME OVERHEATED AND BLEW OUR AFTER ABOUT 2 MONTHS OF RUN TIME. IT SOUNDS LIKE THE THIN ALUMINUM HEADS IS THE SOURCE OF THIS PROBLEM. IS THERE ANY RECALL OR CONCERNS FROM FORD ON THIS PROBLEM. I DO NOT THINK I AM ALONE WITH THIS SITUATION. *TR

Mileage: 118,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, HE HEARD A LOUD NOISE AS THE VEHICLE BEGAN TO SHAKE VIOLENTLY. THE VEHICLE WAS SHUT OFF AND RESTARTED HOWEVER, THE ENGINE ROARED ABNORMALLY LOUD AND EXHIBITED A REDUCTION IN ENGINE POWER. THE CONTACT FOUND A SPARK PLUG SITTING ON TOP OF THE ENGINE, WHICH APPEARED TO HAVE BEEN EJECTED FROM THE ENGINE. THE VEHICLE WAS NOT DIAGNOSED. THE MANUFACTURER WAS NOTIFIED AND STATED THAT NO ASSISTANCE WOULD BE OFFERED. THE FAILURE AND CURRENT MILEAGE WAS 149,500.

Mileage: 149,500

WHILE DRIVING ON MO HWY 150, I HEARD A LOUD POPPING NOISE COMING FROM THE ENGINE COMPARTMENT. I IMMEDIATELY PULLED MY 2002 FORD F-150 KING RANCH 4WD, TO THE SIDE OF THE ROAD AND TURNED OFF THE MOTOR. UPON OPENING THE HOOD I DISCOVERED THE #3 ENGINE CYLINDER SPARKPLUG WAS GONE! AFTER TOWING THE VEHICLE HOME I CONTACTED MY FORD DEALER TO HAVE THE MOTOR FIXED. THE REPAIR BILL WAS $865.00. I WENT ON THE WWW AND DISCOVERED THAT THE FORD MOTORS ARE NOTORIOUS FOR THIS PROBLEM. FURTHER, IF THE PLUG WOULD HAVE STRUCK THE FUEL LINE JUST ABOVE, A FIRE MIGHT HAVE ENGULFED THE VEHICLE. I FEEL THE FORD MOTOR COMPANY SHOULD RECALL ALL THE VEHICLES WITH THIS 5.4 MOTOR AND REPLACE ALL PARTS EFFECTED BY THIS PROBLEM. *TR

Mileage: 87,750

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE VEHICLE SHOOK AND WOBBLED VIOLENTLY THEN FUEL SPEWED FROM THE ENGINE. THE FAILURE RECURRED NUMEROUS TIMES OVER THE COURSE OF FIVE YEARS. THE VEHICLE WAS TAKEN TO A DEALER WHERE THE SPARK PLUG COILS WERE REPLACED. THE FAILURE RECURRED EACH TIME. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 100,000 AND THE CURRENT MILEAGE 226,330.

Mileage: 100,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT AFTER DRIVING AND PARKING THE VEHICLE FOR APPROXIMATELY 15 MINUTES, THE CONTACT FOUND THAT THE VEHICLE HAD CAUGHT ON FIRE. PRIOR TO THE INCIDENT THE CONTACT HAD NOTICED THAT THE ABS WARNING LIGHT WAS ILLUMINATED. THE POLICE AND FIRE DEPARTMENT WERE CONTACTED AND A REPORT WAS FILED. THE VEHICLE WAS LATER TOWED BUT WAS NOT INSPECTED BY A DEALER OR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS CONTACTED AND THEY ADVISED THEM THAT THERE WERE RECALLS ON THE VEHICLE THAT WERE NEVER SATISFIED, BUT THE CONTACT WAS UNSURE OF WHICH RECALLS WERE OPEN ON THE VEHICLE. THE FAILURE AND CURRENT MILEAGES WAS APPROXIMATELY 160,000. *TR

Mileage: 160,000

THE SPARK PLUG STRIPPED THE TREADING ON THE HEAD AN WAS EJECTED FROM THE ENGINE. *TR

Mileage: 145,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, HE HEARD A LOUD NOISE FROM UNDER THE HOOD. THE CONTACT THEN NOTICED GASOLINE SPRAYING OUT OF THE VEHICLE. AFTER FURTHER INSPECTION, HE NOTICED A SPARK PLUG HAD BLOWN OUT THE HEAD OF THE MOTOR. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT THE ALUMINUM IN THE BLOCK WAS NOT STRONG ENOUGH TO HOLD THE SPARK PLUG. THE HOLE WAS RE-THREADED AND A SLEEVE WAS PLACED INSIDE. AFTER THE CONTACT DROVE 50 MILES, THE FAILURE RECURRED. THE VEHICLE WAS TOWED TO A DIFFERENT MECHANIC WHERE THE CONTACT WAS AWAITING DIAGNOSIS. THE MANUFACTURER WAS NOTIFIED BUT OFFERED NO ASSISTANCE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 137,000. UPDATED 4/26/13 *CN

Mileage: 137,000

MY 2002 FORD F150 XLT SUP CAB 4WD V8 HAS BEEN ACTING UP FOR A MONTH OR SO IT STARTED BY ACTING LIKE IT HAD A DEAD BATTERY BUT THAT WASN'T IT WE USED 2 NEW BATTERY'S IN IT SO THE LOCAL MECHANIC SHOP SHOWED US HOW TO REMOVE THE HOT POST HAVE THE TRUCK TURNED ON BUT NOT CRANKED AND WHEN YOU REPLACE THE HOT POST WATCH FOR THE RPM TO RACE TO THE HIGHEST THEN BACK DOWN TO 0 THEN CRANK IT THIS IS A TWO MAN JOB BY THE WAY AND IT WORKED THEN IT JUST STOPPED NEEDING TO BE DONE AND HAS BEEN RUNNING FINE I DROVE IT ON TUESDAY NO PROBLEMS AND TODAY FRIDAY SOMEONE CAME INSIDE AND TOLD ME THE TRUCK WAS CRANKING ON ITS OWN I HAD THE ONLY SET OF KEYS IN MY POCKET SO I THOUGHT IMPOSSIBLE WELL I WENT TO CHECK AND SURE ENOUGH IT WAS TRYING TO START ON ITS OWN I GOT INTO THE TRUCK AND TRIED TO CRANK IT BUT IT WOULDN'T START ON MY 3RD TRY IT TURNED OVER BUT SOUNDED LIKE THE STARTER WAS BANGING INTO SOMETHING AND NOW THAT I HAVE READ MULTIPLE CASES WHERE PEOPLES TRUCK HAS CAUGHT ON FIRE WHILE NO ONE WAS IN IT AND IT HAD NOT BEEN DRIVEN IN A FEW DAYS I WONDER IF THERE TRUCK HAD TRIED TO START ON ITS OWN AND THEY JUST DIDN'T KNOW IT IM GOING TO CALL FORD MOTOR COMPANY TOMORROW BUT THE PEOPLE WHOSE TRUCKS CAUGHT ON FIRE GOT NO HELP FROM THEM IM HOPING THEY WILL HELP ME BEFORE MY TRUCK CATCHES ON FIRE ITS UNDRIVEABLE AT THIS POINT BUT A FIRE WOULD NOT ONLY DESTROY ANY CHANCE OF FIXING IT BUT THE DAMAGE THE TRUCK COULD CAUSE TO OTHER THINGS OR PEOPLE AROUND IT WOULD BE IRREVERSIBLE HAS ANYONE ELSE HAD THERE TRUCK TO CRANK WITHOUT A PERSON OR KEY NEAR IT ? HERE'S HOPING FORD MOTOR COMPANY CARES ABOUT THERE CUSTOMERS. *TR

Mileage: 186,498

WHILE DRIVING DOWN THE ROAD, SPARK PLUG BLEW OUT OF CYLINDER HEAD. ORIGINAL PLUGS IN ENGINE SO NOT A QUESTION OF IMPROPER TORQUE AS FORD CONTENDS. FORD EVEN HAS A NAME FOR THE ISSUE = "SPARK PLUG EJECTION". IMPROPER DESIGN CAUSED IMMEDIATE LOSS OF POWER IN TRAFFIC ON HIGHWAY DURING RUSH HOUR. HAD TO COAST TO SIDE OF ROAD. POTENTIAL FOR FIRE DUE TO UNBURNED FUEL VAPORS ESCAPING CYLINDER BORE INTO ENGINE COMPARTMENT WHICH NOW HAD SPARK COIL EXPOSED DUE TO FAILURE. *TR

Mileage: 85,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, HE HEARD A LOUD POPPING SOUND AND THE VEHICLE DECELERATED. AFTER INSPECTION, HE NOTICED THAT THE SPARK PLUG EJECTED FROM THE CYLINDER HEAD, DAMAGING THE IGNITION COIL. THE FAILURE OCCURRED THREE TIMES. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED ON ANY RECALLS. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 110,000 AND THE CURRENT MILEAGE WAS 185,190.

Mileage: 110,000

WHILE DRIVING 60 MPH I HEARD A LOUD POP FOLLOWED BY DECELERATION AND ENGINE MISFIRE. EXAMINED ENGINE COMPARTMENT AND OBSERVED COMPRESSION AIR FROM #4 SPARK PLUG. OVERHEAD COIL BROKE OFF AND STILL ATTACHED TO #4 SPARK PLUG. GAS FUMES AND STILL SPARKING PLUG WAS A DISASTER WAITING TO HAPPEN SO I HAD THE TRUCK TOWED 150.00. AND 300.00 REPAIR TO RETHREAD CYLINDER HEAD. MECHANIC SAID IT WAS ORIGINAL SPARKPLUGS AND EXAMINED ALL REMAINING PLUGS. # 1 PLUG SEATING WAS DAMAGED UPON INSPECTION AND APPEARED THAT IT WAS ABOUT TO POP OUT ALSO. *TR

Mileage: 138,000

THE #3 PLUG ON THE PASSENGER SIDE TOWARDS THE REAR BLEW OUT OF THE ENGINE. THE ENGINE HAS NEVER HAD THE PLUGS REPLACED. I PURCHASED THE TRUCK NEW FROM FORD IN APRIL 2002. THE TRUCK HAS THE FORD 5.4 TRITON. THE PLUG HAS ALL OF ITS THREADS THE HEAD HAS NO THREADS. THE COIL WAS ALSO DAMAGED WHEN THE PLUG BLEW OUT OF THE HEAD. *TR

Mileage: 82,823

EXHAUST CLAMP THAT HOLDS EXHAUST DAMPER OR COUNTER WEIGHT FELL OFF ( BECAUSE OF RUSTED EXHAUST CLAMP ) WHILE DRIVING AT 50 MILES PER HOUR. ITS QUITE HEAVY AND WAS BOUNCING ON ROAD BEHIND ME ALMOST HITTING MOTORCYCLE FOLLOWING ME. I FOUND MY EXHAUST DAMPER ON SIDE OF ROAD, IF NEEDED FOR INVESTIGATION. *TR

Mileage: 180,000

ON START UP A SPARKPLUG BLEW OUT OF CYLINDER HEAD .... 3RD PLUG TO BOW OUT IN 8 MONTHS OVER 800.00 PER PLUG TO FIX THEN CAUGHT ON FIRE UNDER HOOD......VERY DANGEROUS TO HAVE HAPPEN MAY CAUSE OUR HOUSE TO BURN DOWN IF IN GARAGE.... I CALLED FORD 4 TIMES NO HELP WHAT SO EVER.....BAD COMPANY .....DO NOT ADVISE ......BAD FORD PRODUCTS....THEY NEED TO DO A CLASS ACTION ON FORD ..... *TR

Mileage: 97,000

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT WAS TRAVELING 45 MPH WHEN A POPPING NOISE EMITTED FROM UNDER THE HOOD AND THE VEHICLE DECELERATED ABNORMALLY. THE CHECK ENGINE LIGHT ILLUMINATED AFTER THE FAILURE. THE CONTACT STATED THAT A PRIVATE MECHANIC CONFIRMED THAT THE PASSENGER SIDE COIL FOR A SPARK PLUG BECAME DETACHED. THE MANUFACTURER WAS CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 98,791.

Mileage: 98,791

I WAS DRIVING MY VEHICLE WHEN I HEARD AN EXPLOSION-TYPE SOUND, SIMILAR TO THAT OF A GUNSHOT. THE SOUND STARTLED ME AND CAUSED ME TO VEER OFF THE ROAD CRASHING INTO A BUSH ON SOMEONE'S FRONT LAWN. I RE-STARTED THE VEHICLE AND HEARD A VERY LOUD AND RAPID "POPPING" SOUND FROM UNDERNEATH THE HOOD, WHICH BECAME WORSE AS I ACCELERATED. THE VEHICLE WAS ALSO SHAKING VIOLENTLY AS I ATTEMPTED TO DRIVE HOME, WHICH WAS ONLY 1 MILE AWAY FROM WHERE THE INCIDENT OCCURRED. WHEN I ARRIVED HOME I INSPECTED THE ENGINE COMPARTMENT AND IMMEDIATELY NOTICED THAT THE 2ND SPARK PLUG IN ON THE DRIVER'S SIDE OF THE ENGINE (#6 CYLINDER) WAS BLOWN COMPLETELY OUT OF THE ENGINE HEAD. I CONTACTED MY LOCAL FORD DEALER THE NEXT MORNING AND WAS TOLD TO HAVE THE VEHICLE TOWED TO THEIR SERVICE DEPARTMENT. SHORTLY AFTER ARRIVING, I WAS INFORMED THAT "BLOWN SPARK PLUGS" ARE A VERY COMMON ISSUE WITH THE FORD TRITON 4.6 AND 5.4 LITRE ENGINES. I WAS ADVISED THAT THE SPARK PLUG HOLE WOULD HAVE TO BE RE-TAPPED AND A HELI-COIL KIT INSTALLED. THIS WORK WAS PERFORMED ON 06/08/2012 WITH A TOTAL COST TO ME OF $449.81, NOT INCLUDING THE COST OF THE TOW. I WAS ADVISED BY THE DEALER'S SERVICE DEPARTMENT THAT FORD HAD ISSUED THE FIRST OF SEVERAL TSB'S (TECHNICAL SAFETY BULLETINS) TO ALL OF IT'S SERVICE DEPARTMENTS ACROSS THE US IN MARCH OF 2006 INFORMING THEIR TECHNICIANS OF THE DEFECT IN THE ENGINE'S ALUMINUM HEAD AND THE INCREASING FREQUENCY OF THIS "BLOWN SPARK PLUG" ISSUE. INCLUDED IN THIS TSB WERE INSTRUCTIONS ON HOW TO REPAIR BY USING A HELI-COIL, WHICH IS NOT A FORD PART, NOT COVERED UNDER ANY WARRANTY AND NOT GUARANTEED TO STAY IN PLACE. A RECALL NEEDS TO BE ISSUED. PLEASE SEE THE LINK; I AM ONE OF THOUSANDS WHO HAVE EXPERIENCED THIS ISSUE AND I FEEL THAT THOSE OF US WHO HAVE INCURRED UNNECESSARY COSTS DUE TO FORD'S DEFECT SHOULD BE MADE WHOLE. HTTP://WWW.CONSUMERAFFAIRS.COM/AUTOMOTIVE/FORD_SPARK.HTML. *TR

Mileage: 188,000

STARTED TO HEAR EXHAUST NOISE FROM ENGINE COMPARTMENT ON MY 2002 FORD F150 XLT TRITON V8 4.6L WITH ONLY 95412 MILES FOUND THAT BOLTS THAT HOLD THE EXHAUST MANIFOLD WERE BROKE AND OTHERS NEAR BREAKING AT CYLINDER HEAD THERE IS A DANGER OF FIRE IN ENGINE COMPARTMENT DUE TO HOT EXHAUST GASES AND SAFETY ISSUE REPAIR EXPENSIVE HAVING TO REMOVE BOLT STUDS FROM ENGINE HEAD WITHOUT DOING DAMAGE TO ENGINE HEAD THAT ARE SO RUSTED IN. *TR

Mileage: 95,412