If anyone would like to put in a plug for their repair shop and offer their services, respond to this blog. Please include business name and address and business phone number if you would like. We occasionally have inquiries for names of businesses that will do this repair throughout the USA. Customers should be advised we do not endorse or have any affiliation with the repair centers. Here are a few places that have done this repair, their contact information can be looked up on-line or in a phone book. Ask them about Calvan spark plug insert repair and that you found them on DenLors Blog.

Smith South Plains Ford
Hwy 114 East
Levelland, TX 79336

Wheat Ridge Auto Repair
9205 W. 44th Ave.
Wheat Ridge, CO 80033

Pollard Friendly Ford
3301 South Loop 289
Lubbock, TX 79423

Tri State Tire
110 W. 1st N.
Rexburg, ID 83440

Tunex Auto Care Center
1220 Sage Dr.
Cedar City, UT 84720

Dulles Automotive
44827 Ox Road Unit A
Sterling , VA 20166

Pistners Auto
721 S. St. Marys Rd
St. Marys, PA 15857

Metro Ford
1651 New State Hwy
Raynham, MA 02767

Moritz Machine Shop
4424 E Admiral Place
Tulsa, OK 74115

Demos, I believe this is the question on their website you are referring to:

Q: Why should I not use a coil type insert to fix a stripped spark plug hole?

A: Stainless steel cannot transfer heat fast enough to allow the spark plug to properly cool. It is also very difficult to break off the installation tang during an in-frame repair.

My Response: I agree that repeated heating and cooling with a thin steel wire coil is likely to cause failure. But the Calvan insert is not a thin wire.

… they claim that if you use a steel insert it will transfer heat too slowly for the spark plug to cool and operate at its prescribed heat range and possibly fail a metal to metal contact with the head.

The Calvan insert is steel alloy. The steel alloy shares very similar heating and cooling characteristics to aluminum and is obviously much stronger. As far as the contact surface, the Calvan insert has much more surface area than a wire insert. As of todays date we still have had no failures or altered performance claims from anyone.

Charles, I don’t have a specific shop to recommend in San Francisco but you can use the shop finder link on the right sidebar under blog links. This will take you to iATN (International Automotive Technician’s Network)so you can search for a good automotive repair shop in your area. Those shops and technicians are very well informed and are professional, so you’re better off finding one from there than looking in the local newspaper or yellow pages.

The vehicle can be started immediately following the repair. Full cure time for JB Weld is 15 hours, but I wouldn’t hesitate to start the engine right after the repair. The reason is that the JB Weld is not meant to seal combustion gases, its purpose is to prevent the spark plug insert from ever backing out over time. The insert would more than likely never back out without the JB Weld, but I think of it as extra insurance.

I’m glad this kit worked out well for you.

Calvan only makes the one size insert. I’m not sure why there would be two threads exposed in the head, unless there may be slight differences (in cylinder head depth) depending on the year. I’m sure this won’t be an issue. Over-all this kit seems to be the best repair for this problem, it’s the one I recommend and the one I would use myself.

Ron, Yes this insert relacement kit is designed to be done on the vehicle with the intake and heads in place. The video shows the job performed on an engine stand for illustration purposes.

Jim,

The video does say to epoxy or JB weld the insert but it is NOT a Heli-coil. The Helicoil is not solid (it’s a wire coil), the Calvan insert is solid, so it will not allow the substance used to go between the threads and contact the spark plug threads. You should never allow epoxy to contact the spark plug threads, unless it is in an attempt to remove the old Helicoil upon removal, like in our blog on How to Remove a Helicoil. If I were you, I would try to remove the old Helicoil since it is no longer holding compression and use the Calvan 38900 to install a permanent repair.

Paul, I would recommend using the “Shop Finder” on the right column under “BlogRoll” you can narrow your search for a local shop to do the repair.

Jan, yes the repair kit this article specifically addresses the Ford 4.6 and 5.4 blowout issue. The 2003 is the same as prior years. Some 2004 Ford 5.4’s have a different problem (they break upon removal) see our tech article for more information.

Todd,

Thanks for the inquiry/comment. Yes, This tool is designed to be used in the vehicle. Sometimes, ALL of the cylinders are fitted with the Calvan inserts to eliminate the chance of having another blowout in one of the other cylinders.

Once the (heater hoses pulled and secured out of the way) coils are removed and the fuel rail is loosened and repositioned, enough access is gained to use the kit. The guide, drill and tap are designed to be used with an air ratchet so it’s like using a right angle drill. Since the guide keeps the drill and the tap straight, it’s not required to physically see straight down at the cylinder being worked on. The fact that the heads do not have to be removed makes using this kit well worth the effort. Less down time and a lot less expensive repair that is much stronger than the original threads. We’ve sold hundreds of these without failures, unlike Heli-coil and other brands that use thinner material. See the Calvan 38900 product for more information and keep in mind every kit comes with a DVD showing the procedure (same as the YouTube footage but higher quality).

What is the thread pitch and diameter of the outside of the ford 4.6L spark plug repair insert?

We now have the Mount-9200DLT which is the same kit as the Calvan – they are made by Horizon Tool company. They are available in more of our warehouses so they we can reduce transit time to our customers.

Brent, Thanks for taking the time to let us know how the repair went. I agree with your added tips. I’m sure everyone that reads them will too!

Rod, Calvan only makes one size insert and it is the largest one available in any brand that I am aware of. I did see what you’re talking about on Timesert’s website. They say an extra tool is required on the 1L2E PI heads when installing their insert. If you wanted you can ask Horizon Tools directly (about the 38900) to see if they have any additional information. My viewpoint is that it’s not a factor with Calvan because it is larger and the taper in the 1L2E PI heads will be drilled out anyway. With the 38900, after the drilling, tapping and replacement insert is installed it’s a done deal.

Mike, I’m assuming there was a plug blown out and an insert was installed. Most shops are not going to provide a warranty in this case, since they have no idea how the engine ran prior to the blowout. It’s best to use a borescope or inspection scope to be sure there is no debris remaining in the cylinder prior to completion of the job. If a kit other than the Horizon style one was used, the noise you hear could be compression leaking past the insert. Other than that, if you still suspect valve leakage, a leak down tester can be used to help pinpoint the problem. As far as getting the shop to cover part or any of the additional time needed, I don’t think there’s much of a chance of that.

Slats, thanks for taking the time to let us know how your repair worked out, glad it went well. I’m sure the parts house brand repair kit manufacturer didn’t realize how ridiculous their directions were when they said “hit it with a hammer but not too hard!”

I too have never understood why the kit comes with only 6 inserts. We do have individual ones in case someone decides to do all of them.

HotRaud, I’m fairly certain that the kit will work on DOHC engines, since the SOHC motor uses the same spark plug number. However, I know you need to find out for sure – Calvan/Horizon Tools can be contacted by phone at 1.800.537.1077 during the week from 8:00 AM to 4:30 PM Eastern Standard time.

Tim, the spark plug blow out repair kit works on 1996 to 2005 2 valve engines – your 2001 falls into the correct date range. Readers that have newer 3 valve engines should be aware that this kit is NOT for those engines.

Joe, Either is fine, since it is only to keep the insert from backing out when changing spark plugs in the future.

Chuck, thanks for the feedback. It’s important to note for our readers that “hit with a hammer” is NOT part of the directions for the Calvam/Horizon tool – but is a step mentioned in a competive brand.

Squirrel, there is a growing need for a kit to work on the 3V engines like you have. The 3v engines don’t have the “blow out” problem like in the the 2v engines. But, the threads do get damaged sometimes when working the plugs back and forth too much to remove siezed plugs. I’m hoping that Horizon tools will make a kit to cover the 3v engines, but we currently don’t have a product to offer for spark plug thread insert replacement for 3v engines. We have had one customer that mistakenly tried the Calvan 38900 on his 3 v engine – he had to get a machine shop to make an insert based on measurements from the O.D. of the 389-100 insert and the spark plug measurements. Still cheaper and less work than removing and replacing the cylinder head.

That was not the same issue that a previous customer had (with a 3v engine). In their case the kit worked as it should to drill and tap the hole, but the insert didn’t fit the plug.

There may be several different depths of spark plug wells for the 3 valve heads? If the bit isn’t long enough the thread tap won’t be either.

With the 2 valve heads they are all the same depth. I don’t recommend trying to use the Calvan 38900 on 3 valve engines since it’s is designed only for 3v. Unfortunately at this time we don’t have a product for your application (3 valve engine).

I used the insert kit to repair my ‘01 5.4 engine right rear plug (probably the most difficult to repair). I’ve been an aircraft structure mechanic and inspector for over 20 years. In the past, I have drilled critical holes in a lot more expensive things than my trucks “entire” value. I used the kit and an air ratchet to bore the new hole, but went much slower than the demonstration CD showed / instructed. I did not use the air ratchet to cut the new threads. I did not trust the speed or “feel” (my opinion) using an air ratchet for this so I did it by hand, but it went well and I waited over 20 hours for the JB weld to set the insert. This system is the best that I have researched and believed in before using. Simplicity in use and instruction is the key. This system is a winner. I have driven the truck now for a week, no problems.

Just have spark plug issue with my 03 ford expedition. Been doing some reading on the cause and possible solution. Is the calvan still a viable option?

Alright, Sounds great. Where do I find this kit and how much does it cost?
2000, 5.4, F-150
Calvan 38900 Is the correct kit?