Thank you, I really like your channel/ I have an 08 F250 Super duty with 5.4 and have been dealing with the spark plugs for days. You have helped guide this old shade tree mechanic a great deal.
This is like the 5th time you have saved my truck from the junkyard. I don't ever want to get rid of her and thanks to you and these videos I won't have to. Thanks for being there and keep up the most excellent work.
I just did mine in a police interceptor and this kit worked great, the results look very professional, above all there's no place or shop can warranty this job and IS NOT CHEAP. It's worth it try to repair it yourself. 👍👍👍
Thanks Makuloco, I have watched many of your videos, and as usual you are exactly right. So glad that we have a guy like you in our corner. Please keep up the great videos, and we totally appreciate it.
I personally use JB Weld with that same kit you have. Just make sure it is not the kwikset version of JB Weld. Have never had one come back out. I work at A Ford dealership in California. Enjoy your content on this channel.
Really appreciate your information and knowledge! I was deployed and the #8 blew out on my 4.6 and the one mechanic I could find initially told me $250 for boot, plug and labor. Keep in mind I am 6k miles away and he at least sent me an email telling me my motor is shot and needs the engine replaced for $6,000! I had my wife get the truck removed from his business and it has been parked ever since. He did not charge me anything but since being back I still have not found anyone in my area to give me a second opinion. The engine has 170k miles and I have religiously taken care of this truck. It does not leak and I think it still has life. It is a 2004 STX and I have accomplished all the prevenative maintenance. I am the single owner and have changed 2 light bulbs and the brakes on this truck in it's life span. This has been a good truck. I'm throwing it out there in the hopes you or someone on this page might know a reputable shop in the New Orleans area that might help me out. Thanks!
I used the large head tap kit on a roadside repair on a 4.6 Crown Vic before. I took an angle grinder to make the head a 5/8ths. Worked great other than the next ten miles the engine chattered from ceramic in the combustion chamber. Once that pulverized the compression went to 120 or so and they kept driving fine.
The shops are probably charging the several hours to pay for the $500 kit in one job. They are probably getting the kit just to do that one particular job and do not want to wait and spread the cost over several jobs. As always a great video. Good job!
Also Dorman makes a kit, I only bring it up because I ran into this on my own 5.4. I did not install it, I found it already installed when I bought the truck. The kit contains whats looks like a tap with the center drilled out to accept a 3 valve spark plug. Now it was working fine when I bought the truck. During the spark plug change, I found this thing, did some research to find out what it was. I removed it before I knew what it was and installed the regular plug. Well 2 years and 10k miles later I have yet to have the plug blow out. Don't know if I just got lucky or what. LOL Great videos by the way.
Dorman makes a little kit for like $30 that uses an insert and a newer long plug. It works surprisingly well. It's a good option for diy and you can get it at any parts store. It's literally a two step process. Super easy.
Van-cal had an issue with the quality department making the inserts. Some people installed the inserts and they were not seating all the way. Go to hardware store and buy a 3/4 x 16 nut and screw it on to each insert to make sure the threads are smooth. A mechanic on YT posted a video about the inserts. I forgot his channel name. I bought the Van-cal kit for 245.00 with free shipping. I checked each insert and found 1 bad one. I'm glad i found that video before messing up a job i'm doing. That would of been a nightmare. Nice clean video and easy to understand FTM. Watched your video to see what groove the C-clip clipped onto. Thanks.
I've done quite a few of these at work. I use q bond on the ear of the coil with success. I also use the fix a thread kit with the too big of a head on the tap. I just grind down the head of the tap until it will fit down the spark plug hole with a socket on it. Thanks for your videos.
FordTechMakuloco good point. Luck was on my side when I grinded it, lol.The tap I grinded down has seen its last job. I was just gonna grab another one but now that you brought that up, I'm gonna purchase the one you recommend. Thanks.
Ended up going for the timesert kit for a 03 4.6 2v. About the same price for me and worked well. I would add going and checking the torque on the plugs every few oil changes.
I just had a customer come in for this job. I told them before they brought the vehicle that I don't enjoy doing this job, but it's a Sunday and they're trying to get out of town. #2 Cyl so pretty easy. I use JB Weld on the insert threads. I've actually had these come in with a previous insert that backed out-threads on both ends were okay, JB'ed it and put it back in. Worked fine. I charge 2 hours, 3 possibly if it's a #4 or 8 cyl.
I now understand why I was able to acquire my T-bird for cheap. The previous owner must of needed this done, and didn't want to spend money. It was done when I acquired the car and now I can confirm what the shavings were. Sic:)!
Thank you for this video!!! I just took my f150 into the shop and they charged me 9 hours of labor and also removed the head. Cilinder head resurface, cilinder head power wash, head gasket kit with bolts ($279) which rediculous price, new front crank shaft seal, head gasket r&r included valve carbon removal (9hr at $60/hr)=$540... Be carful guys where you take you cars to get fixed and make sure you do your research!!!! Total he was trying to charge me $1000 when all i neded is to replace blowen out spark plug thats it!
I seem to remember when they first came out with this engine. The first TSB was to fix the blown out 1 with some old kit for Escorts back when then remove and retorque the other 7 due to under torque at the plants.
I have this kit and put my first insert in today in 30 min.if you need to repair a plug, only use this kit if you don't, you'll be doing it twice the others won't hold.
Great vids…one question…my 18 yr old grandsons first vehicle …we bought it on the cheap thinking we could use this “kit”…2010 F150 vin W 4.6 #3 cyl 2v…but this kit states up to yr. 2003…any thoughts?? Thanks Al
you make it very clear I had no problem doing this on my on thanks and made it clear why the cheap ones won't last. just to weak material. heavy duty is what I was looking for. thanks for video. my search was over thanks to you!!
Now that I finished the exhaust manifold replacement, this is next. At 260,000K she is due for some repairs. I think I know WHY the shops are charging 5 hours; The kit is $230 divided by 4 is about $60/hr + 1 hour for actual labor. Add on another for profit & mark-up. The first customer pays for the tools! Thank you for your great videos!
I used one of those thread savers a few years ago on my Duratec engine and it failed. I fixed it the other day a Big Sert kit. I was dubious about those tread savers for good reason. My truck has a Triton 2 valve and I will definitely use a Cal Van kit to repair a blown out plug on it.
Had this happen 3 times on my old crown Vic which was my first car... a tip I learned luckily before I did this was to get some kind of air blower or try to turn the motor over with the plug out and fuel relay disconnected to shoot the aluminum shavings out of the cylinder so it doesn't get down into the oil pan. Just a little tip if it isn't already in the video
I can tell you by experience, the #4 plug is extremely difficult to reach, especially with the tool you showed. It was a very involved and timely process, which would justify the 4 hours of labor charged out. The truck did have 200k on it, and when I chose to change the rest of the plugs out, found that half were Motorcraft and the other half Champion. This was an under-maintained vehicle with many hard to move fasteners and electrical connectors. The New York State rust belt doesn't help either. It can be a regional thing, but certainly a lack of proper maintenance thing. It is more difficult to change the plugs on this engine, but you only have to do it every 100k, so it's all relative. Great video, BTW, just wish the actual cylinder was shown getting the insert put in. I realize the issue with getting right in there, but hey, I like watching someone say "No big deal" and "Watch this" at the same time! Just glad I wasn't working on the 3 valve Triton this time!
Great video and very helpful 👍🏼. I have a question. I have an 04 gt 4.6 2 valve and about 2 months ago my car threw a plug. I pulled the plug out and it had already been re threaded, there was a helix coil around the plug. Is there another repair kit I can buy to re thread it or will I have to buy a new head?
Mr. Brian, CalVan Repair? Would you encourage the Calvan inserts be installed not as a repair but as a prevention from plug blowouts. Had to pull a cracked intake from a 230K+ 02 - 5.4l 2v eng. While it's apart I'm considering installing CalVan inserts in all the cylinders purely to PREVENT plug blowouts. Currently plug threads are stock and not damaged (borescope checked.) I am a "If it ain't Broke DONT Fix it kind of guy" but I try to be smart/ prudent as well. In addition, with the less than desirable Ford factory spark plug thread configuration my concern is that a blowout could severely damage the head even beyond what the Calvan Kit is designed to repair. Your thoughts are appreciated.
hi just to let you know a friend of mine had is plugs changed and they broke 3 plugs and cost him 700.00 from ford dealer in Lethbridge Alberta . thanks' for great video
Hello Just repair one and put everything back together and the coil pack seems like it sits higher, then the other cylinders that are not repair ? Would that be a issue ?
Do the heads need to be out before this procedure? Or can it be done without taking out the heads? Please let me know. I just installed new head gaskets n heads bolts on my 6.8l. Still waiting on few things to get here before shes ready to run. Thanks
I just started replacing plugs in my 2003 f150 5.4 and the previous owner used a dorman repair insert and when I pulled the plug out the insert broke off will that drill bit get that out for me thanks
Hello! I ordered the kit to fix my 2v 4.6L. Just a question, i do not have a air ratchet, but will be getting one. What do i need to do this job without any hiccups? air ratchet or impacting air ratchet.? and what specs of the ratchet is required? thanks in advanced!
Hey, I have an 08 f150 4.6, I have just started to get a Bucking and hesitation on Acceleration after 3rd gear. from what i have been reading most are saying Bad coil/Plugs, I had new ford plugs at 105,000 km. and i'm at 123 now. Just wondering if you have had any experience with this issue.? p.s fuel filter and air filter are new. Thank you for your time.
I have a 2005 Ford F-150 that blew a spark plug. 4.6 engine. The kit you show is for years 1996 to 2003. Is there a different kit for 2005 years to use? Thank you for your help.
hopefully you get back quickly lol, im doing the repair tomorrow.... I have been hearing a squeaking tapping sound on this new/used expedition I traded my Chevy truck for 1998 5.4l for about a week and finally today leaving Napa I started it and pop went the plug on start up..broke the ignition coil....i got it to work, I'm a heavy equipment mechanic so i know my way around a vehicle pretty well. #4 plug was the blow out so I pulled the coil out and then the plug came out in 1 piece and didn't look like anything was damaged but the plug bottom from flopping around...I pulled the other plugs as well on that bank and they were just covered in soot/ash. I want to just stick a good plug back in there and tighten it without the insert? if I ordered the nice kit you have in the video saying if just retorque a new plug and it fails.... how can I get a drill in number 4 cylinder being under the cowl by the bulkhead?
Great video man, just had this happen to cylinder #4 on my 6.8l. I'd love to see you demonstrate this on the big triton. #4 is tough, but #5 and #10 may be easier through the glove box! Lol. It stinks that nobody makes a v10 insert kit, just v8's. Those extra 2 inserts get pricey with some of these kits.
The clip is a good idea, but I use an o-ring on mine. It won't go past it and o-rings are cheap and usually stocked. Love this kit though. Never had a problem with my drill bit but I did think it took a bit to bite and start cutting.
I REALLY ENJOYED YOUR VIDEO AND HAD A QUESTION OR TWO, I HAD THE SAME PROBLEM WITH MY FORD EXPEDITION 0N CYLINDER 2 AND TO IT TO A REPAIR SHIP WHO ADVISED THAT IT NEEDED TO BE RE-THREADED, AND AFTER THE SERVICE THE TRUCK RAN GOOD FOR ABOUT 2 WEEKS AND THEN IT BLEW OUT. THE THREAD USED WAS HALF THE SIZE OF THE SPARK PLUG THREAD AND ABOUT AS THIN AS THE BLACK ONE YOU SHOWED ON YOUR VIDEO. I LIVE IN SAVANNAH GA AREA AND WAS WONDERING IF YOU CAN RECOMMEND WHO YOU WOULD CONSIDER IN THIS CASE. ALSO WOULD THAT KIT WORK ON MY EXPEDITION
You explained how to get the intake and outtake valves closed with the rubber plug and shop air, and you said the cylinder needs to be down, but how do you get the cylinder down if you find that it is up? I just discovered your channel and love it! Please just explain how to get the cylinder all the way to the bottom. Thanks!
Are you saying the Calvan system will grind out a broken insert from a previous repair? I have an insert , the top third separated and bottom 2/3 is in the plug hole, all the way back on No.4 of my 5.4. Very nervous about using an easy out on it.
great concept of the calvan kit but my question is what if the plug that blowed out was one of the ones under the firewall. how will i be able to drill out the hole
Thank you very much, very good step by step,.. I have a 2001 XLT f150 5.4 and I can only find a insert kit for the 3 valve engine. what is the difference between the 3 valve and 2 valve spark plug threads, or seems like the kits are the same! Is there difference in years as well,..again Thank You!
Got the Cal-Van kit for the 2v 4.6. However, it states it can only be used up to model year 2003. Will i have any issues using this kit on a 2008 Crown Victoria P-71? Thanks for all of the time and effort and helpful information you put into your videos.
Hi. Great videos for Ford people! I have a 2002 Mustang GT Auto. 120k miles. I have had one of the spark plugs blowout. I had it repaired. Is there any way to prevent this from happening to any of the other spark plugs? Thanks!
Seems like a design flaw that Ford should split the bill for. Had one blow out, dealer wanted $400 for one plug. A fiend had the tool so I did it in a half hour.
My drill bit keeps binding and I live in Canada so the kit is hard to come by, have to wait a week or more....wondering if I can thread out with the save-a-thread tap and then use the drill bit on a larger diameter hole to see if it will work???? Very expensive here in Canada 🇨🇦 for this quality control oversite....
Hi Brian, question?! I bought a 98 E350 V 10 140k about month ago. I want to tune it up i'm not sure if plugs has ever blown out, what can I do to prevent it from happening after I change them? Thanks
What were the engineers at Ford thinking, only using three threads for the spark plugs, in the 5.4 2v engine? Think there would be a recall, or actions being taken to solve this issue, for us owners of this particular f150 5.4 2v.
Very nice video !! Question what is the outer diameter of that cal van insert?? And is there a smaller kit from cal van i used the dorman kit it lasted about three years but now those threads are bad
i have a question about temperatures. my sons truck will not fit through my garage door so this repair will have to be done outside,...........and its cold out. 15 to 30 degrees out. will this present a problem?,.............should i find a garage and thaw the truck out first?
Hello, nice video. I tried to google search to see if any ford rangers blow out spark plugs to, but no luck. Do you know if any ford ranger years has this same problem?
I have a 2000 f150 5.4 #3 And #4 spark plugs are rounded completely from previous owner and are stuck in the head I now have the head off how can I get them out. Any ideas would be helpful. Thanks
Brian, I'm having a slow start issue with my 04 F150 5.4. It is now taking about 10 cranks instead of 1 before the engine will start. It was doing it occasionally now it's all the time. Feels like I'm losing fuel pressure. Is there a check valve in the fuel line somewhere? Any ideas where I should look? Thanks
Just a quick warning about using any borescope for internal engine inspection. If you want to use a tool such as an angled mirror for looking at the valves, make absolutely certain that the tool is magnetic! Don't ask me how I know....
Ordered this kit and was the wrong size. M spark plugs are the other model. They are skinnier and longer. I found the thread size . They are m12×1.25. Do they make this kit with this size threads? I can't find it. I had to order a different kit.
Will this last kit you used work on a DOHC 4.6? I have a mach 1 that blew a coil pack and damaged the spark plug threads along with it and would like fix it asap.
Brian, I got a 2v 5.4, plug #7 didnt blow out, but when I removed it for a normal maintenance plug change, only the porcelain came out. The thread "basket" and ground strap are seized in the head. I've tried a #5 easy out, wouldn't touch it, broke two sockets from the torque. Help!
Your videos are awesome!! Thanks for sharing all the knowledge and experience you have! I'm currently dealing with this on my 03 e250 5.4 v8 (16v?) will this kit work with that engine? And If it does should I get the atd 5400 instead? Worried about the reamer not functioning as with yours.. please help!! Thx!!
Very nice video! Just a few questions, the pistons should be at bottom dead center? And is the reamer/ drill bit driven in with just a socket wrench or on an actual drill? Finally, aside from the Loctite, what holds the insert in when the plugs are removed? Thanks and have a great Memorial Day.
Fair warning to those attempting this job. Check for old helicoil in the plug hole before you drill. Which I did but couldn't see it. I used my air ratchet to drill and it was tough and took a while, I thought it was because I have a small compressor that wasn't powerful enough. Low and behold when I was checking to make sure I got all the shavings out I found a piece of helicoil on top of the piston. The helicoil job was done by a previous owner. So if you don't see helicoil before drilling and have troubles drilling, stop and check again. You don't want my new problem.
Update: after a day and half of failed attempt after failed attempt. I finally got the old piece of helicoil out of the cylinder without removing the head. WOO HOO!!!!!!!
You mentioned the threads are not sufficient, especially in the early models. When did they add more threads? I just bought a 2008 F150, 4.6, and am wondering if I am going to have to deal with this problem. Great video.
I was on Highway when this happend. Coil pack was still loosely in its hole. Could not find the plug. Is it possible for the plug to fall into the cylinder?
hi I have a 2005 Ford f250 with a 5.4 motor that has a blown out spark plug kit in it but the insert broke any ideas on how to remove a previous spark plug fix kit insert.
What engineer at Ford thought, "Hey, lets use a long plug with three threads on these Triton motors..what could possibly go wrong? Then all their superiors figured it would be a good idea to produce this engine for 19 years and counting!
+FordTechMakuloco Just about to turn 300,000 miles on my original '97 F150 4.6... 5 sets of plugs, haven't had this issue yet. No major repairs, never had the heads off. The intake manifold gaskets were the most involved repair so far. 19 years and yep, I'm counting.
+FordTechMakuloco I have a 98 Ford Crown Victoria the spark plug blew out with the insert on the plug is it good to try to put in another had this car about five years didn't know it all ready had one in it can it be fixed
i yes did one on my 1998 f-150 4.6 v8 i did used napa helicoil used for 2 day end its miss fire on the same cylinder any idea replaced coil pack spark plug wires fuel injector still miss fire any idea why
Hi. I did the Cal Van repair on my 99 Expy 5.4L back in 2010. This summer, I had my local Ford dealer replace all the spark plugs. The other day, the sleeve shot out with the plug. I have no idea how that would have happened. Now, the threads for the sleeve are stripped out in the head. What are the options after that? I'm guessing a new head. I'll have to do it myself as I don't work now as I'm disabled. Unfortunately, funds are very tight.
I spoke to an Engineer at the Cal-Van company. He said that the fact that my cal-van sleeve blew out is because the aluminum in the heads that Ford used is crap and is weak metal. He advised that I can "travel uncharted territory" and use a 3/4" - 16 Heli-Coil Kit to make new threads to accommodate the Cal-Van Sleeve to accommodate the spark plug. How long it will last (if it does at all) is the question. Other option is a new head. That's a major job for a DIY guy.
If this repair has been done to my expedition 5.4L can it do it again? i am not sure what kit was used. i am having same problem again with the sameone that i had a shop repair about a year ago
Is there any other loctite to use with these. Like 272 or 271. One of the two is rated to 450 degrees. I can’t find 266 in any auto parts stores and just a small bottle online is like 30 bucks. Any help would be appreciated. Also does it matter if it’s Romeo heads? I know it will make about 3/8” higher in the chamber but any issues with that?
the shop is saying my spark plug hole can't be fixed because the Helicoil Falls right in the hole. is it possible for me to use aluminum weld on my 04 Ford Expedition
i searched comments but didnt see, i only see 8 inserts, its a v10 so im short 2? what link do you have to buy the same inserts packs? fir the extra 2 i need? thanks
I'm curious to know what my local machine shop used on my '02 Mustang because it blew back out in just over 170 miles, engine caught fire, and burned the whole car down. I insisted that they use the nut insert rather than a helicoil for this reason and they said they used the same one they use at the dealer but who knows. I'm definitely glad I had comprehensive insurance!
That's what I was thinking, hindsight being 20/20 I wish I had just done the repair myself but the price of the timesert kit was more than what they wanted for the whole repair.
The real question here: can you do this process on all 8 cylinders without removing the fuel rail? On my 2005 4.6 F150 that fuel rail is directly over the plugs, barely enough room to pull the coil out. I just discovered my #3 cylinder has been (poorly) repaired this way because the insert came out during a plug change. Looked like a tiny smear of JB weld on the threads was the only thing holding it in. Fun times
Hey if anyone could give me advice I would appreciate it. I have a 97 f150 4.6 with a broken plug in cylinder #4 broken above the threads. I already got the porcelain busted out of the plug with a variety of tools mainly my hammerdrill. Now the threads are stuck. With dried up pb blaster on the head.. I will now drill it out and put a insert. any suggestions on how to clean the cylinder of all the metal shavings very good? I see everyone blowing shavings out of a dry cylinder, mine isn't so dry. I figure if I get water spraying from the top down I can just vacuum it all up easy. or should I not use water?
what boroscope do you recommend? trying to do this the best way possible on my 01 v10 excursion. don't want to cause anymore damage, or need to do more repair than is necessary. excellent video btw. i usually search for your stuff when i start a job I haven't had much experience with yet.
I am rebuilding a 1998 V10 6.8L. The heads are pulled off. One of the cylinders already has a heli-coil. The other cylinder threads look very warn. I'm thinking I should repair them while the heads are off. Do you recommend the same CalVan kit when the heads are off or is there a cheaper alternative like the Advance Auto Parts kit with the large tap head? I assume you can tap it from the other side with the heads off.
I hAVE A 1998 e150 CLUB WAGON, 5.4. I JUST BOUGHT IT, IT HAS 197000 ON THE DIAL, AND iT STATES THEY GET CHANGED EVERY 100k. sHOULD I CHECK A PLUG, AND SEE IF I NEED TO DO THIS?
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Spark Plug Thread Repair Kit I recommend-
amzn.to/29j4jk1
Loctite 266-
amzn.to/3IlT9KN
Cheap Wifi Endoscope I use-
amzn.to/3Kqi4yJ
Thank you, I really like your channel/ I have an 08 F250 Super duty with 5.4 and have been dealing with the spark plugs for days. You have helped guide this old shade tree mechanic a great deal.
How about putting a thick oil in the cylinder to trap the shavings then use a evac tank to suck it out?
This is like the 5th time you have saved my truck from the junkyard. I don't ever want to get rid of her and thanks to you and these videos I won't have to. Thanks for being there and keep up the most excellent work.
I just did mine in a police interceptor and this kit worked great, the results look very professional, above all there's no place or shop can warranty this job and IS NOT CHEAP. It's worth it try to repair it yourself. 👍👍👍
Thanks Makuloco, I have watched many of your videos, and as usual you are exactly right. So glad that we have a guy like you in our corner. Please keep up the great videos, and we totally appreciate it.
I personally use JB Weld with that same kit you have. Just make sure it is not the kwikset version of JB Weld. Have never had one come back out. I work at A Ford dealership in California. Enjoy your content on this channel.
This just happened on my way home from work today. Very happy the cylinder head doesn't need to come off. Great video
Really appreciate your information and knowledge! I was deployed and the #8 blew out on my 4.6 and the one mechanic I could find initially told me $250 for boot, plug and labor. Keep in mind I am 6k miles away and he at least sent me an email telling me my motor is shot and needs the engine replaced for $6,000! I had my wife get the truck removed from his business and it has been parked ever since. He did not charge me anything but since being back I still have not found anyone in my area to give me a second opinion. The engine has 170k miles and I have religiously taken care of this truck. It does not leak and I think it still has life. It is a 2004 STX and I have accomplished all the prevenative maintenance. I am the single owner and have changed 2 light bulbs and the brakes on this truck in it's life span. This has been a good truck. I'm throwing it out there in the hopes you or someone on this page might know a reputable shop in the New Orleans area that might help me out. Thanks!
Same thing just happened to me except it was cylinder 3 and I was quoted $8,000 for a engine swap
WOW, Excellent Demonstration! Thanks
I used the large head tap kit on a roadside repair on a 4.6 Crown Vic before. I took an angle grinder to make the head a 5/8ths. Worked great other than the next ten miles the engine chattered from ceramic in the combustion chamber. Once that pulverized the compression went to 120 or so and they kept driving fine.
😳🤯🫣
They don't call them the "stealership" for no reason. This is why I work on my own cars. Thanks to video's like this, it helps us DIY'ers.
The shops are probably charging the several hours to pay for the $500 kit in one job. They are probably getting the kit just to do that one particular job and do not want to wait and spread the cost over several jobs. As always a great video. Good job!
Also Dorman makes a kit, I only bring it up because I ran into this on my own 5.4. I did not install it, I found it already installed when I bought the truck. The kit contains whats looks like a tap with the center drilled out to accept a 3 valve spark plug. Now it was working fine when I bought the truck. During the spark plug change, I found this thing, did some research to find out what it was. I removed it before I knew what it was and installed the regular plug. Well 2 years and 10k miles later I have yet to have the plug blow out. Don't know if I just got lucky or what. LOL Great videos by the way.
Nice job! You displayed exceptional functional expertise. TH-cam needs more vids like yours.
New Ford's are total junk anymore
I've be a Ford man until trition motors came out ,Ford wake up
Dorman makes a little kit for like $30 that uses an insert and a newer long plug. It works surprisingly well. It's a good option for diy and you can get it at any parts store. It's literally a two step process. Super easy.
What parts would I need for the kit?
I bought the calvan kit off Amazon and did it myself. It was pretty straightforward.
I used this kit, the insert cracked after a year. Now trying this ADT KIT.
No no no dont use that kit theyd are half assed not even the rigt plug and pure garbage that will lead to more damge when it blows out
Van-cal had an issue with the quality department making the inserts. Some people installed the inserts and they were not seating all the way. Go to hardware store and buy a 3/4 x 16 nut and screw it on to each insert to make sure the threads are smooth. A mechanic on YT posted a video about the inserts. I forgot his channel name. I bought the Van-cal kit for 245.00 with free shipping. I checked each insert and found 1 bad one. I'm glad i found that video before messing up a job i'm doing. That would of been a nightmare. Nice clean video and easy to understand FTM. Watched your video to see what groove the C-clip clipped onto. Thanks.
I've done quite a few of these at work. I use q bond on the ear of the coil with success. I also use the fix a thread kit with the too big of a head on the tap. I just grind down the head of the tap until it will fit down the spark plug hole with a socket on it. Thanks for your videos.
Michael Herbert Yeah I thought of doing that but figured I would make it uneven and wobble when I used it.
FordTechMakuloco good point. Luck was on my side when I grinded it, lol.The tap I grinded down has seen its last job. I was just gonna grab another one but now that you brought that up, I'm gonna purchase the one you recommend. Thanks.
Ended up going for the timesert kit for a 03 4.6 2v. About the same price for me and worked well. I would add going and checking the torque on the plugs every few oil changes.
I just had a customer come in for this job. I told them before they brought the vehicle that I don't enjoy doing this job, but it's a Sunday and they're trying to get out of town. #2 Cyl so pretty easy. I use JB Weld on the insert threads. I've actually had these come in with a previous insert that backed out-threads on both ends were okay, JB'ed it and put it back in. Worked fine. I charge 2 hours, 3 possibly if it's a #4 or 8 cyl.
This may be a spark plug rethread video for specific Ford issues, but I learned a lot generally toward other applications as well.
I now understand why I was able to acquire my T-bird for cheap. The previous owner must of needed this done, and didn't want to spend money. It was done when I acquired the car and now I can confirm what the shavings were. Sic:)!
BTW Great video!!!!!!
Thank you for this video!!! I just took my f150 into the shop and they charged me 9 hours of labor and also removed the head. Cilinder head resurface, cilinder head power wash, head gasket kit with bolts ($279) which rediculous price, new front crank shaft seal, head gasket r&r included valve carbon removal (9hr at $60/hr)=$540...
Be carful guys where you take you cars to get fixed and make sure you do your research!!!! Total he was trying to charge me $1000 when all i neded is to replace blowen out spark plug thats it!
I seem to remember when they first came out with this engine. The first TSB was to fix the blown out 1 with some old kit for Escorts back when then remove and retorque the other 7 due to under torque at the plants.
I have this kit and put my first insert in today in 30 min.if you need to repair a plug, only use this kit if you don't, you'll be doing it twice the others won't hold.
Great vids…one question…my 18 yr old grandsons first vehicle …we bought it on the cheap thinking we could use this “kit”…2010 F150 vin W 4.6 #3 cyl 2v…but this kit states up to yr. 2003…any thoughts?? Thanks Al
I love how you explain things.....what ever you do.....never stop teaching....thank you so much.....03 Vic
you make it very clear I had no problem doing this on my on thanks and made it clear why the cheap ones won't last. just to weak material. heavy duty is what I was looking for. thanks for video. my search was over thanks to you!!
+Steve Falls Yup this kit is definitely a heavy duty permanent repair.
Now that I finished the exhaust manifold replacement, this is next. At 260,000K she is due for some repairs. I think I know WHY the shops are charging 5 hours; The kit is $230 divided by 4 is about $60/hr + 1 hour for actual labor. Add on another for profit & mark-up. The first customer pays for the tools! Thank you for your great videos!
I used one of those thread savers a few years ago on my Duratec engine and it failed. I fixed it the other day a Big Sert kit. I was dubious about those tread savers for good reason. My truck has a Triton 2 valve and I will definitely use a Cal Van kit to repair a blown out plug on it.
very clear step by step over view of this repair sure made my day go a lot easier Thanks
Had this happen 3 times on my old crown Vic which was my first car... a tip I learned luckily before I did this was to get some kind of air blower or try to turn the motor over with the plug out and fuel relay disconnected to shoot the aluminum shavings out of the cylinder so it doesn't get down into the oil pan. Just a little tip if it isn't already in the video
Thanks for the video, There are so many kits that it was hard to know which is best.
man, you should be an instructor!! good job on explaining how it works
Thanks!
I can tell you by experience, the #4 plug is extremely difficult to reach, especially with the tool you showed. It was a very involved and timely process, which would justify the 4 hours of labor charged out. The truck did have 200k on it, and when I chose to change the rest of the plugs out, found that half were Motorcraft and the other half Champion. This was an under-maintained vehicle with many hard to move fasteners and electrical connectors. The New York State rust belt doesn't help either. It can be a regional thing, but certainly a lack of proper maintenance thing. It is more difficult to change the plugs on this engine, but you only have to do it every 100k, so it's all relative. Great video, BTW, just wish the actual cylinder was shown getting the insert put in. I realize the issue with getting right in there, but hey, I like watching someone say "No big deal" and "Watch this" at the same time! Just glad I wasn't working on the 3 valve Triton this time!
You are doing a great job, with your video!!!!!!.keep the good work, replaced my spark plugs 2005 ford f150 5.4 2005.
With the help of your videos.
Great video and very helpful 👍🏼. I have a question. I have an 04 gt 4.6 2 valve and about 2 months ago my car threw a plug. I pulled the plug out and it had already been re threaded, there was a helix coil around the plug. Is there another repair kit I can buy to re thread it or will I have to buy a new head?
Mr. Brian,
CalVan Repair?
Would you encourage the Calvan inserts be installed not as a repair but as a prevention from plug blowouts.
Had to pull a cracked intake from a 230K+ 02 - 5.4l 2v eng.
While it's apart I'm considering installing CalVan inserts in all the cylinders purely to PREVENT plug blowouts.
Currently plug threads are stock and not damaged (borescope checked.)
I am a "If it ain't Broke DONT Fix it kind of guy" but I try to be smart/ prudent as well. In addition, with the less than desirable Ford factory spark plug thread configuration my concern is that a blowout could severely damage the head even beyond what the Calvan Kit is designed to repair.
Your thoughts are appreciated.
hi just to let you know a friend of mine had is plugs changed and they broke 3 plugs and cost him 700.00 from ford dealer in Lethbridge Alberta . thanks' for great video
Hello
Just repair one and put everything back together and the coil pack seems like it sits higher, then the other cylinders that are not repair ?
Would that be a issue ?
Do the heads need to be out before this procedure? Or can it be done without taking out the heads? Please let me know. I just installed new head gaskets n heads bolts on my 6.8l.
Still waiting on few things to get here before shes ready to run. Thanks
I just started replacing plugs in my 2003 f150 5.4 and the previous owner used a dorman repair insert and when I pulled the plug out the insert broke off will that drill bit get that out for me thanks
Hello! I ordered the kit to fix my 2v 4.6L. Just a question, i do not have a air ratchet, but will be getting one. What do i need to do this job without any hiccups? air ratchet or impacting air ratchet.? and what specs of the ratchet is required? thanks in advanced!
Hey, I have an 08 f150 4.6, I have just started to get a Bucking and hesitation on Acceleration after 3rd gear. from what i have been reading most are saying Bad coil/Plugs, I had new ford plugs at 105,000 km. and i'm at 123 now. Just wondering if you have had any experience with this issue.? p.s fuel filter and air filter are new. Thank you for your time.
I have a 2005 Ford F-150 that blew a spark plug. 4.6 engine. The kit you show is for years 1996 to 2003. Is there a different kit for 2005 years to use? Thank you for your help.
I just had this happen on 4.6 2002 Mustang GT with 160K. Good Video
hopefully you get back quickly lol, im doing the repair tomorrow.... I have been hearing a squeaking tapping sound on this new/used expedition I traded my Chevy truck for 1998 5.4l for about a week and finally today leaving Napa I started it and pop went the plug on start up..broke the ignition coil....i got it to work, I'm a heavy equipment mechanic so i know my way around a vehicle pretty well. #4 plug was the blow out so I pulled the coil out and then the plug came out in 1 piece and didn't look like anything was damaged but the plug bottom from flopping around...I pulled the other plugs as well on that bank and they were just covered in soot/ash.
I want to just stick a good plug back in there and tighten it without the insert?
if I ordered the nice kit you have in the video saying if just retorque a new plug and it fails.... how can I get a drill in number 4 cylinder being under the cowl by the bulkhead?
Great video man, just had this happen to cylinder #4 on my 6.8l. I'd love to see you demonstrate this on the big triton. #4 is tough, but #5 and #10 may be easier through the glove box! Lol. It stinks that nobody makes a v10 insert kit, just v8's. Those extra 2 inserts get pricey with some of these kits.
Great Video! I'm about to buy a 97 4.6 f150 and these spark plugs are the biggest thing i'm worried about!
The clip is a good idea, but I use an o-ring on mine. It won't go past it and o-rings are cheap and usually stocked. Love this kit though. Never had a problem with my drill bit but I did think it took a bit to bite and start cutting.
I REALLY ENJOYED YOUR VIDEO AND HAD A QUESTION OR TWO, I HAD THE SAME PROBLEM WITH MY FORD EXPEDITION 0N CYLINDER 2 AND TO IT TO A REPAIR SHIP WHO ADVISED THAT IT NEEDED TO BE RE-THREADED, AND AFTER THE SERVICE THE TRUCK RAN GOOD FOR ABOUT 2 WEEKS AND THEN IT BLEW OUT. THE THREAD USED WAS HALF THE SIZE OF THE SPARK PLUG THREAD AND ABOUT AS THIN AS THE BLACK ONE YOU SHOWED ON YOUR VIDEO. I LIVE IN SAVANNAH GA AREA AND WAS WONDERING IF YOU CAN RECOMMEND WHO YOU WOULD CONSIDER IN THIS CASE. ALSO WOULD THAT KIT WORK ON MY EXPEDITION
You explained how to get the intake and outtake valves closed with the rubber plug and shop air, and you said the cylinder needs to be down, but how do you get the cylinder down if you find that it is up? I just discovered your channel and love it! Please just explain how to get the cylinder all the way to the bottom. Thanks!
Are you saying the Calvan system will grind out a broken insert from a previous repair? I have an insert , the top third separated and bottom 2/3 is in the plug hole, all the way back on No.4 of my 5.4. Very nervous about using an easy out on it.
clearly explained and yes automotive Con's ruin honest Tech's but honest work will prevale good instructions and tool choices Mark
great concept of the calvan kit but my question is what if the plug that blowed out was one of the ones under the firewall. how will i be able to drill out the hole
You attach the reamer to a standard 3/8" ratchet or air ratchet- amzn.to/2hZ9IzG
Thank you very much, very good step by step,.. I have a 2001 XLT f150 5.4 and I can only find a insert kit for the 3 valve engine. what is the difference between the 3 valve and 2 valve spark plug threads, or seems like the kits are the same! Is there difference in years as well,..again Thank You!
+JoeT001 Big difference you want to use this kit for 2v engines like yours-amzn.to/1Y2URmY
I have a v6 mustang needing this repair. Not much room the cylinder is near the fender area. Which kit or stuff would I need? I have the 3.8L
THANK YOU FOR PRESERVING THE CORPORATIONS GOLD 🇺🇸🏁
Got the Cal-Van kit for the 2v 4.6. However, it states it can only be used up to model year 2003. Will i have any issues using this kit on a 2008 Crown Victoria P-71? Thanks for all of the time and effort and helpful information you put into your videos.
Hi. Great videos for Ford people! I have a 2002 Mustang GT Auto. 120k miles. I have had one of the spark plugs blowout. I had it repaired. Is there any way to prevent this from happening to any of the other spark plugs? Thanks!
Seems like a design flaw that Ford should split the bill for. Had one blow out, dealer wanted $400 for one plug. A fiend had the tool so I did it in a half hour.
Which kit? I can't find a kit for 32v 4.6 mach 1
My drill bit keeps binding and I live in Canada so the kit is hard to come by, have to wait a week or more....wondering if I can thread out with the save-a-thread tap and then use the drill bit on a larger diameter hole to see if it will work???? Very expensive here in Canada 🇨🇦 for this quality control oversite....
that kit works in the new model of trucks f150 2004 triton to? I
would li to know please
Hi Brian, question?! I bought a 98 E350 V 10 140k about month ago. I want to tune it up i'm not sure if plugs has ever blown out, what can I do to prevent it from happening after I change them? Thanks
What were the engineers at Ford thinking, only using three threads for the spark plugs, in the 5.4 2v engine? Think there would be a recall, or actions being taken to solve this issue, for us owners of this particular f150 5.4 2v.
Very nice video !! Question what is the outer diameter of that cal van insert?? And is there a smaller kit from cal van i used the dorman kit it lasted about three years but now those threads are bad
i have a question about temperatures. my sons truck will not fit through my garage door so this repair will have to be done outside,...........and its cold out. 15 to 30 degrees out. will this present a problem?,.............should i find a garage and thaw the truck out first?
Will the repair work on a '97 Ford F-150 5.4l engine that blew the same plug a second time? It was done once already before I bought the truck
Hello, nice video. I tried to google search to see if any ford rangers blow out spark plugs to, but no luck. Do you know if any ford ranger years has this same problem?
No
I have a 2000 f150 5.4 #3 And #4 spark plugs are rounded completely from previous owner and are stuck in the head I now have the head off how can I get them out. Any ideas would be helpful. Thanks
Brian, I'm having a slow start issue with my 04 F150 5.4. It is now taking about 10 cranks instead of 1 before the engine will start. It was doing it occasionally now it's all the time. Feels like I'm losing fuel pressure. Is there a check valve in the fuel line somewhere? Any ideas where I should look? Thanks
Just a quick warning about using any borescope for internal engine inspection. If you want to use a tool such as an angled mirror for looking at the valves, make absolutely certain that the tool is magnetic! Don't ask me how I know....
BADASSS !! dude you know your stuff my respects to you sir I was bummed out but I'm going to try this !! thank you !!
Ordered this kit and was the wrong size. M spark plugs are the other model. They are skinnier and longer. I found the thread size . They are m12×1.25. Do they make this kit with this size threads? I can't find it. I had to order a different kit.
Will this last kit you used work on a DOHC 4.6? I have a mach 1 that blew a coil pack and damaged the spark plug threads along with it and would like fix it asap.
I am curious as well, I have a 96 Cobra 4.6 DOHC and a plug blew out. Having a hard time finding a 4v kit or even info!
Brian, I got a 2v 5.4, plug #7 didnt blow out, but when I removed it for a normal maintenance plug change, only the porcelain came out. The thread "basket" and ground strap are seized in the head. I've tried a #5 easy out, wouldn't touch it, broke two sockets from the torque. Help!
Your videos are awesome!! Thanks for sharing all the knowledge and experience you have! I'm currently dealing with this on my 03 e250 5.4 v8 (16v?) will this kit work with that engine? And If it does should I get the atd 5400 instead? Worried about the reamer not functioning as with yours.. please help!! Thx!!
Very nice video! Just a few questions, the pistons should be at bottom dead center? And is the reamer/ drill bit driven in with just a socket wrench or on an actual drill? Finally, aside from the Loctite, what holds the insert in when the plugs are removed? Thanks and have a great Memorial Day.
thanks your vidio made life a little easyer thx
Fair warning to those attempting this job. Check for old helicoil in the plug hole before you drill. Which I did but couldn't see it. I used my air ratchet to drill and it was tough and took a while, I thought it was because I have a small compressor that wasn't powerful enough. Low and behold when I was checking to make sure I got all the shavings out I found a piece of helicoil on top of the piston. The helicoil job was done by a previous owner. So if you don't see helicoil before drilling and have troubles drilling, stop and check again. You don't want my new problem.
Update: after a day and half of failed attempt after failed attempt. I finally got the old piece of helicoil out of the cylinder without removing the head. WOO HOO!!!!!!!
You mentioned the threads are not sufficient, especially in the early models. When did they add more threads? I just bought a 2008 F150, 4.6, and am wondering if I am going to have to deal with this problem. Great video.
No yours are fine.
I have this issue right now with my 2008 F150 4.6 2V
but 315 000 KM tho
I was on Highway when this happend. Coil pack was still loosely in its hole. Could not find the plug. Is it possible for the plug to fall into the cylinder?
No the plug blew out for sure
hi I have a 2005 Ford f250 with a 5.4 motor that has a blown out spark plug kit in it but the insert broke any ideas on how to remove a previous spark plug fix kit insert.
What engineer at Ford thought, "Hey, lets use a long plug with three threads on these Triton motors..what could possibly go wrong? Then all their superiors figured it would be a good idea to produce this engine for 19 years and counting!
+cbsctomh That engine was the most reliable they have built in a long long time besides this issue of course.
+FordTechMakuloco Just about to turn 300,000 miles on my original '97 F150 4.6... 5 sets of plugs, haven't had this issue yet. No major repairs, never had the heads off. The intake manifold gaskets were the most involved repair so far. 19 years and yep, I'm counting.
+FordTechMakuloco I have a 98 Ford Crown Victoria the spark plug blew out with the insert on the plug is it good to try to put in another had this car about five years didn't know it all ready had one in it can it be fixed
i yes did one on my 1998 f-150 4.6 v8 i did used napa helicoil used for 2 day end its miss fire on the same cylinder any idea replaced coil pack spark plug wires fuel injector still miss fire any idea why
Hi. I did the Cal Van repair on my 99 Expy 5.4L back in 2010. This summer, I had my local Ford dealer replace all the spark plugs. The other day, the sleeve shot out with the plug. I have no idea how that would have happened. Now, the threads for the sleeve are stripped out in the head. What are the options after that? I'm guessing a new head. I'll have to do it myself as I don't work now as I'm disabled. Unfortunately, funds are very tight.
I spoke to an Engineer at the Cal-Van company. He said that the fact that my cal-van sleeve blew out is because the aluminum in the heads that Ford used is crap and is weak metal. He advised that I can "travel uncharted territory" and use a 3/4" - 16 Heli-Coil Kit to make new threads to accommodate the Cal-Van Sleeve to accommodate the spark plug. How long it will last (if it does at all) is the question. Other option is a new head. That's a major job for a DIY guy.
If this repair has been done to my expedition 5.4L can it do it again? i am not sure what kit was used. i am having same problem again with the sameone that i had a shop repair about a year ago
Is there any other loctite to use with these. Like 272 or 271. One of the two is rated to 450 degrees. I can’t find 266 in any auto parts stores and just a small bottle online is like 30 bucks. Any help would be appreciated. Also does it matter if it’s Romeo heads? I know it will make about 3/8” higher in the chamber but any issues with that?
This was extremely helpful, thank you very much!
the shop is saying my spark plug hole can't be fixed because the Helicoil Falls right in the hole. is it possible for me to use aluminum weld on my 04 Ford Expedition
Awesome video thank you. I just bought the Lisle 65900 kit for the triton 6.8, any opinions on that one? Hasn't arrived yet.
James King It looks just ok I like mine better due to the larger inserts with better heat transfer.
i searched comments but didnt see, i only see 8 inserts, its a v10 so im short 2? what link do you have to buy the same inserts packs? fir the extra 2 i need? thanks
How about putting a thick oil in the cylinder to trap the shavings then use a evac tank to suck it out?
I'm curious to know what my local machine shop used on my '02 Mustang because it blew back out in just over 170 miles, engine caught fire, and burned the whole car down. I insisted that they use the nut insert rather than a helicoil for this reason and they said they used the same one they use at the dealer but who knows. I'm definitely glad I had comprehensive insurance!
+UnsulliedSpy There is no way a time sert kit like the dealer uses failed.
That's what I was thinking, hindsight being 20/20 I wish I had just done the repair myself but the price of the timesert kit was more than what they wanted for the whole repair.
+UnsulliedSpy Yeah that is why I recommend this kit, works very well and never a problem.
Unfortunately I trusted a "professional" shop to do a better job than I thought I would have done and it cost me my car and everything inside of it.
What's the difference between the 2v & 3v kits? Varying well diameter?
The real question here: can you do this process on all 8 cylinders without removing the fuel rail? On my 2005 4.6 F150 that fuel rail is directly over the plugs, barely enough room to pull the coil out. I just discovered my #3 cylinder has been (poorly) repaired this way because the insert came out during a plug change. Looked like a tiny smear of JB weld on the threads was the only thing holding it in. Fun times
Hey if anyone could give me advice I would appreciate it.
I have a 97 f150 4.6 with a broken plug in cylinder #4 broken above the threads. I already got the porcelain busted out of the plug with a variety of tools mainly my hammerdrill. Now the threads are stuck. With dried up pb blaster on the head..
I will now drill it out and put a insert. any suggestions on how to clean the cylinder of all the metal shavings very good?
I see everyone blowing shavings out of a dry cylinder, mine isn't so dry.
I figure if I get water spraying from the top down I can just vacuum it all up easy.
or should I not use water?
Thanks for the knowledge
what boroscope do you recommend? trying to do this the best way possible on my 01 v10 excursion. don't want to cause anymore damage, or need to do more repair than is necessary. excellent video btw. i usually search for your stuff when i start a job I haven't had much experience with yet.
This is the one I use all the time it works great for the price- amzn.to/2bhfP21
+FordTechMakuloco excellent. thanks man. I'll have to post on here when I finish the job.
I am rebuilding a 1998 V10 6.8L. The heads are pulled off. One of the cylinders already has a heli-coil. The other cylinder threads look very warn. I'm thinking I should repair them while the heads are off. Do you recommend the same CalVan kit when the heads are off or is there a cheaper alternative like the Advance Auto Parts kit with the large tap head? I assume you can tap it from the other side with the heads off.
I hAVE A 1998 e150 CLUB WAGON, 5.4. I JUST BOUGHT IT, IT HAS 197000 ON THE DIAL, AND iT STATES THEY GET CHANGED EVERY 100k.
sHOULD I CHECK A PLUG, AND SEE IF I NEED TO DO THIS?
Excellent video by the way. Enough to make me subscribe. Thank you.