Comments on: Ford Spark Plug Blow Outs – Oversize Inserts and FAQ’s

By: Thom77

Thom77 — Thu, 25 Feb 2010 18:55:31 +0000

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?

By: dennisb - Auto Tool Sales

dennisb - Auto Tool Sales — Sun, 21 Feb 2010 12:29:58 +0000

Bradley, The Calvan/Horizon kit has been our recommenedation for several years now – it’s the kit I would use if I had a blown plug in an applicable vehicle.

By: bradley evans

bradley evans — Sun, 21 Feb 2010 07:55:20 +0000

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?

By: dennisb - Auto Tool Sales

dennisb - Auto Tool Sales — Sat, 13 Feb 2010 13:43:43 +0000

Tim, Thanks for the testimonial. I understand your aprehension, not wanting to use an air ratchet – however, using an air ratchet is safe because of the guide that is included. I agree with you though, on tapping the threads, I would do this part by hand also. It certainly doesn’t hurt to allow the JB to “set” as long as you did but for our readers – It isn’t absolutely necessary to wait that long. Good work Tim and thanks again for your comments!

By: TimC01F2505.4

TimC01F2505.4 — Sat, 13 Feb 2010 09:22:56 +0000

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.

By: Squirrel

Squirrel — Sun, 07 Feb 2010 22:39:19 +0000

Well, that really stinks, LOL.

Thank you for all your help, Dennis. I’ll be calling Calvan/Horizon in the morning for a definitive solution.

Again, I REALLY appreciate your help, and I’ll post up what they come up with.

By: dennisb - Auto Tool Sales

dennisb - Auto Tool Sales — Sun, 07 Feb 2010 21:56:09 +0000

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).

By: Squirrel

Squirrel — Sun, 07 Feb 2010 21:02:22 +0000

O.K., well when I put the guide into the head, the milling bit bottoms out on the guide before even touching the plug bore… any ideas why? is there a different length bit? because the tools fit perfectly into the case they came in, I’m assuming the kit is correct, but they just don’t reach…???

By: dennisb - Auto Tool Sales

dennisb - Auto Tool Sales — Sun, 07 Feb 2010 20:57:58 +0000

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.

By: Squirrel

Squirrel — Sun, 07 Feb 2010 19:47:40 +0000

Thanks for the quick reply, Dennis. Since I have the kit “in hand”, and although I completely understand that the kit is NOT intended for the 3V engine, is it the tool depth deficiency that is the problem?

I know that the spark plug DOES fit the insert I.D., I know that the tools in the kit DON’T reach far enough into the head to bore and thread.

What’s the exact issue besides the tools need to be longer? Is there an insert/bore O.D. clearance issue?

Thank you GREATLY for replying promptly… on Superbowl Sunday, no less. WOW!!