OVERALL CYLINDER HEAD CONDITIONS OBSERVED THROUGH COURSE OF REPAIR TO CYLINDER # 6

REPAIR PROBLEM:

The number six sparkplug on my 5.4L FORD TRITON V-8 ejected a spark under driving conditions, thus destroying the sparkplug threads in the cylinder head.  Additionally the coil pack and spark plug were rendered useless. The ignition coil COP (Coil Over Plug) mounting ear was sheared off and the COP was slammed into the fuel rail. Luckily the fuel rail was not compromised.

REPAIR SOLUTION:

The cylinder head was repaired using the BIG-SERT kit, specifically manufactured for the 5.4L FORD TRITON V-8. This kit is manufactured by TIME FASTENER COMPANY, INC.  FORD won’t recognize this as a repair solution, however the kit cost of $300 is one-tenth of the cylinder head replacement cost. The kit performed as advertised, well worth the money.

WHAT I FOUND:

The following table summarizes the physical condition of the sparkplugs in the engine. Four of the eight cylinders had a problem. Cylinders 1-4 are on the passenger side, number 1 is closest to the firewall. Cylinders 5-8 are on driver side, number 8 is closest to firewall. All sparkplugs were checked and ultimately re-torqued to factory specification.

SPARKPLUG STATUS 5.4L TRITON V-8, F-250 SD, AT 81,000 MILES
CYL No.	CYLINDER HEAD PLUG BORE CONDITION	COIL BOOT CONDITION	COMMENTS / OBSERVATIONS PRIOR TO RE-TORQUE
1	Clean, shiny	Clean (grey color)	Sparkplug tight
2	Slight combustion^1 fouling	Slight combustion fouling	Sparkplug loose^2
3	Heavy combustion^3 fouling	Heavy combustion fouling	Sparkplug so loose it could be removed by hand. Cleaned bore / sparkplug seat.
4	Clean, shiny	Clean (grey color)	Sparkplug tight
5	Clean, shiny	Clean (grey color)	Sparkplug tight
6	Slight combustion fouling	Slight combustion fouling	Spark plug that blew out of the cylinder head. BIG-SERT used to repair head.
7	Slight combustion fouling	Slight combustion fouling	Sparkplug loose^2
8	Clean, shiny	Clean (grey color)	Sparkplug tight

1- Combustion fouling appears as a light to dark brown deposit, depending on severity.

2- Required little effort with ratchet to remove the sparkplug.

3- Heavy dark brown deposit, somewhat difficult to remove.

‘SPECIAL’ TOOLS REQUIRED:

1. BIG-SERT repair kit.

2. Contact / Brake cleaner.

3. Small hose attachment for shop vac.

4. (2) six-foot step ladders and 2”x10”x 10’ plank.

5. 12 gauge shotgun bore swab.

The contact / brake cleaner is good for removing deposits. The 12 gauge bore swab soaked in the contact cleaner worked great for cleaning the bore and sparkplug seat. The small vacuum hose was used to remove cleaner/debris from the head and cylinder bores. The step ladders and plank were used to span the engine compartment. By laying across the plank access to the work was easier and prevented balancing over the engine compartment.