Summary: Ford spark plug blowout repair is covered in this article for 4.6, 5.4 & 6.8 liter engines. There are different brand insert repairs available for this Ford spark plug problem, however they are not all as effective and long lasting as the solution we recommend. Many Ford dealers want to charge thousands to replace the cylinder heads, when our repair can be done in the vehicle for a fraction of the cost. We sell some competitive brands like Lisle and Helicoil, however the Horizon made Calvan 38900 (Mount.9200 same w/different labeling) is the best repair system on the market today. We’ve sold hundreds of these, saving Ford owners a ton of money in the process. In the following article we’ll explain why this should be the next and last repair purchased for this particular repair.

This links to the entire article on our main site.

Tags: Ford, Spark, Plug, Blow, Out, Problems, How, to, Repair

Unique Ford spark plug design can easily break when removed

When changing Ford spark plugs it’s good to be aware of the potential of breaking them in certain models. In this repair article, find out which ones are susceptible to separating when being removed. Learn how to remove them without breaking them and how to remove them if they do break. Denlors Auto Repair blog has had several articles about removing broken sparkplugs in Ford vehicles. In addition to Rotunda Separated Spark Plug Remover, we offer several less expensive options of removal tools. Compared to Ford Rotunda special service tools, we save our customers a lot of money, when removing broken spark plugs.

Which Ones To Look Out For

Affected vehicles include; 4.6, 5.4 and 6.8 3V engines found in many 2004-2008 Ford Mustangs, Expeditions, F150’s, Motor-homes, Explorer Sport Trac, Mercury Mountaineers, Lincoln Navigators and the Lincoln Mark LT. Ford has recently came out with a new TSB that supersedes the first ones, that may prevent breaking the sparkplugs to begin with. We have included TSB links towards the bottom of this repair article, courtesy of the Ford Motor Company.

The Short Version

The updated procedure consists of 7 pages (see the PDF links below) basically says to back the sparkplugs no more than 1/8″ to 1/4″ of a turn. Then use a small amount of carburetor cleaner in the sparkplug well and allow time for the cleaner to make it’s way down to the electrode shield. The idea is to loosen the carbon buildup around the electrode shield to allow sparkplug to be removed without breaking it. The process may need to be repeated several times in order for it to work properly. Furthermore the TSB states that a torque wrench must be used to prevent excess pressure from being applied when working the spark-plug back and forth. If the torque exceeds 33 foot-pounds, the porcelain could break. Caution is also advised to prevent the possibility of putting too much carburetor spray down the well, if this is done excessively the engine can become hydro-locked. I can only imagine the frustration involved in trying to remove these wacky sparkplugs and then ending up with a hydro-locked engine!

How’d That Work Out?

So what happens if the TSB 08-7-6 procedure has been followed when changing the spark plugs and a sparkplug still breaks?  As mentioned before we have several options for removing Ford sparkplugs when they break. The first alternative to the Ford rotunda sparkplug removal tool (303-1203) is the Calvan (CAL 39100 – ET391). This tool is basically a copy of the Rotunda 303-1203 at a much lower cost. This tool is used the same as the 303-1203. It  can only be used if the porcelain did not stay inside the electrode shield. The porcelain must be removed first to use either of these tools. Ford’s method uses a 303-1398, the Calvan equivalent is the CAL39200. This approach uses pins that are lock-tighted into the center of the porcelain where the electrode pin was. After the Loctite dries a puller is used to remove the broken porcelain.

Lisle Method

Another option is the Lisle 65600 Ford broken spark plug remover. We’ve done an entire auto repair article featuring this tool and it’s different method of dealing with broken spark plug porcelain. That particular repair blog, includes pictures of the tool in use. Also there are some testimonials from guys that used the Lisle tool. Whichever method is used, it’s still a lot better than removing the cylinder head. Hopefully with the new procedure, removing the spark plugs intact may be possible and no specialty tools will be needed to begin with. 

Ford TSB for Spark Plug Removal – see all 7 pages below.

Ford TSB 08-7-6 Page 1   Ford TSB 08-7-6 Page 2  Ford TSB 08-7-6 Page 3

 Ford TSB 08-7-6 Page 4 Ford TSB 08-7-6 Page 5  Ford TSB 08-7-6 Page 6

 Ford TSB 08-7-6 Page 7

More TSB’s can be accessed on-line along with detailed repair information. Use the instructions needed now and log back in for other repair projects at a later date, all for ONE low fee. Visit Mitchell’s eAuto Repair, access the same repair data Mitchell provides professional shops everywhere.

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Tags: Changing, Ford, Spark, Plugs, 4.6, 5.4, 6.8, Ford, TSB, 08-7-6

Calvan 11/16″ drill bit used with air ratchet and 1/2″ socket.

DenLors tools has sold hundreds of the Calvan spark plug repair kits and has had no reported failures. We’ve answered many questions about Ford spark plug thread repairs over the last couple of years and have included them in various places on our site. Now in this auto repair blog ALL of the frequently asked questions to date are posted here in one central location, if you don’t see your question answered, feel free to use the comment form and ask. Included here are questions about repairing spark plug holes after Lisle, Time Sert, Big Sert, or other brands that are thicker than the Heli-Coil, but still have managed to fail and allow the spark plug to blow out AGAIN. We are not out to discredit or slam any other spark plug insert company, we just know from our customer feedback what works and what just works for awhile. The questions below answer questions from real customers with this real problem. We recommend the Calvan Ford spark plug insert repair kit as the best solution, the following will help show why.

Question:  Are there different size or oversize inserts available for the Calvan insert tool and are they included?

Answer:  There is only one size thread insert for the Calvan repair kit and 6 are included. There is only one size because once the Cal Van is installed, it will not blow out and there is no need for an oversize insert. A competitive brand  called “Timesert” has an oversize insert in case theirs fails, it’s called the Big Sert. The Calvan insert is even larger than the BigSert and Cal Van’s larger stronger design is one of the reasons it can last the life of the cylinder head.  To date the Calvan insert is the largest insert available, that’s the reason it can be used when competing brands fail.  

Question:  I have a 1999 Ford F150 with a 4.6 liter Triton engine with 126,000 miles on it. The number 3 spark plug blew out of the cylinder head. I called my local repair shop and was told that this was a common problem with this design engine because of the extremely thin (aluminum) casting in the spark plug area of the engine head, there is only about five threads for a spark plug. How is the Calvan insert better?

Answer:  While it is true there are only five threads for the spark plug in this design engine for the spark plug and the Calvan repair insert has five spark plug threads as well, the Calvan spark plug insert is steel not aluminum and the insert itself is held in place with ten external threads. The Calvan spark plug insert improves the design and durability at fraction of the cost of replacing the cylinder heads; and if replacing the heads they would have the same design weakness.

Question:  I am selling my truck as fast as I can get a spark plug to stay in long enough to get rid of it. I wanted to use a heli-coil because I won’t have to drill, but the thread tool isn’t long enough to reach in the spark plug recess, any suggestions?

Answer:  I personally recommend the Calvan spark plug repair kit because it is a better repair, but if you would rather use the thinner Heli-coil insert, the HEL5396-14 has the longer thread tool than the standard Heli-coil kit.

Question:  I have Ford van that has had a TimeSert installed previously, it has blown out and I want to know if the Calvan insert will work since the Time Sert has left a bigger hole now?

Answer:  Yes, the Calvan spark plug repair insert is larger and has worked well for our customers before, saving the expense of replacing the heads. Read on for more information.

Question:  I bought a rebuilt head and come to find out one of the spark plug holes had a repair insert, it blew out last week. The cylinder head has a warranty, but I cannot afford the down time of pulling thead all over again. Will the Calvan insert repair this hole?

Answer:  Yes, the Calvan insert is a thicker beefier repair that you don’t have to worry about. And I always tell our customers that when purchasing a rebuilt head of this type to be aware of the possibility that inferior repair inserts may be in the head. Buying a brand new head would insure that there are no cheap inserts, but you would be stuck with the original weak design. The Calvan thread insert repair saves down time, money and is stronger due to the material being steel alloy instead of aluminum like the original threads.

Question:  I need to know the size or dimension of the outside of the insert, to know if it will be large enough to repair the spark plug hole threads that have already been fixed once before?

Answer:  The outside diameter of the insert is .73″ or 18.65mm, this is measuring on the most outer part of the threads. If a HeliCoil or Timesert was used before in the original repair this will work well.

Question:  I have an insert that blew out after an engine rebuild, I can’t afford the down time to have the engine pulled AGAIN. The insert that’s still on the spark plug is not a thin Heli-Coil, it appears to be a Big Sert, which is the Time Sert oversize thread repair. My question is; Will the Calvan thread insert work in an engine after the BigSert has blown out? The outside diameter of the Big Sert is .63″ or 16mm.

Answer:  Yes, I can say this because the drill bit included in the Calvan 38900 spark plug repair kit is 11/16″ (.6875″ or 17.4mm) so what you’re telling me is you have a smaller hole than what the drill bit size is in our kit. So as long as the previous repair was drilled in the center, the Calvan will work great. Also the Calvan has a guide that fits in the spark plug recess so drilling and tapping will be centered every time, if you have a good view of where you’re working or not.

Question:  Does the CalVan insert accept the same spark plug or will I have to remember to use a different spark plug in the repaired port?

Answer:  The CalVan insert uses the same spark plug and has the identical taper and same number of threads, just stronger steel not aluminum.

Question:   The price for one insert seems high, are you sure I don’t get more than one insert for this price?

Answer:   I understand this seems like a lot but for an insert of this quality it’s like many things in life, you get what you pay for. Who wants to trust a weaker design insert to hold in a spark plug, if it fails on a coil over plug design it may break a $50 plus coil, require the job to be done over again, or worse cause extensive engine damage requiring the replacement of the head.

Question:  How long will the Calvan spark plug repair last?

Answer:  The Calvan inserts are designed to last the lifetime of the engine and are stronger than the original threads.

Calvan’s leak down tool to determine when the valves are closed.

Question:  Time Sert says “The only 100% way to know the valves are not open is to remove the valve cover and inspect the cam, making sure that it is not depressing the valves on the damaged spark plug hole.” Do I have to remove the valve cover with the Calvan Ford spark plug insert tool kit?

Answer:  No. The Calvan tool kit allows the mechanic to verify valves are closed with an included cylinder leak detector. Plug the rubber stopper from the leak detector into the spark plug hole with a low amount of air from an air compressor going through the hose. The rubber cone will pop out of the spark plug hole when the valves are closed. The video shows this as well.

Question:  How do I know all the aluminum metal shavings are out of the cylinder?

Answer:  A borescope is used to make sure all foreign debris is removed. A video inspection scope can be used as well, we have a fairly inexpensive video based scope, that in our opinion is better and easier to view than the fiber optic borescope shown in use in the instructional video.

Calvan’s metal sleeve or guide is used to center the drill bit and the tap.

Question:  I’m afraid I might start drilling or tapping the hole crooked, am I going to damage my head beyond repair?

Answer:  With the Calvan specialty tool kit that we sell, since it is made specifically for Ford 4.6, 5.4 and 6.8 Triton engines, it has a guide that fits into the spark plug recess to perfectly guide the drill and the tap making the repair centered, even in hard to access areas.

Question:  Will my spark plug be properly grounded through the engine, since the insert will have JB weld on the threads?

Answer:  I’ve only had one person ask this. The answer is yes. JB weld or Loctite with some other brand inserts is being used on the threads, but there is a large enough percentage of metal to metal contact that provides ground, to allow proper firing of the spark plug.

Question:  The Ford cylinder repair kit instructional video (showing the repair done with the engine on a stand) is good, but can this repair be done in the vehicle?

Answer:  Yes, the video is showing how the kit is used with an engine on a stand, however the tool kit is designed to be used on an engine that is in the vehicle.

Question:  There doesn’t seem to be much room under the cowl area of my truck. How can I drill in that tight area?

Answer:  This repair kit is used in tight areas, on trucks and even in vans. The drill bit, which is used in the guide so the hole is drilled in the correct position. And to allow drilling to be done in confined areas, the drilling is actually done with an air ratchet. The drill bit accepts a 1/2″  socket that is used with your air ratchet, so drilling is done on a right angle. The guide is also used with the thread tap, so making a perfectly centered hole is easy.  

Linking: Please reference this article when quoting, linking to this page is welcomed and appreciated. If you are new to linking a page. 1. Left click the link; http://www.denlorstools.com/autoblog/2008/12/ford-spark-plug-blow-outs-oversize-inserts-and-faqs/ to highlight 2. Right click, select copy 3. Right click and paste to forum, blog web page etc. Thanks! Disclaimer: Repair tips are designed for informational purposes only, without warranty of any kind, in no event shall the author of this site be liable for any consequential, incidental or direct damages sustained in the course of using the information in this article.

Tags: Ford, Spark, Plug, Blow, Outs, Oversize, Inserts, FAQ\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\'s, timesert, bigsert

See the quality difference in the Heli-Coil (top) & the Calvan (bottom)

In this automotive repair/tool blog we cover Ford spark plugs blown out of cylinder heads, it’s still a huge problem. To date we have sold hundreds of Calvan spark plug thread insert tool kits and have had no one call back to say it was too hard or it didn’t work. The included video makes the spark plug insert repair easy to understand and answers all the questions about how this job can be done in the vehicle saving thousands of dollars. We are commonly asked if the Calvan spark plug repair kit will work after TimeSert, Heli-Coil or some other thin, weak repair has failed and have blown out AGAIN. The answer is yes, Calvan inserts are much thicker than the competitor’s inserts and will work much like an over-size oil drain plug will work in a stripped out oil pan. Since the Calvan insert is not just a coil of wire like the Heli-Coil it is much stronger. And since the Calvan insert is thicker than the Time Sert, many times it can be used when the Time Sert is spit out.

Tags: time, sert, ford, spark, plug, blowout, spit, auto, automotive, repair, tool, triton, 4.6, 5.4, 6.8, insert