CalVan Automotive Tools

Calvan 38900-1 4.6-5.4 & 6.8 Ford Spark Plug Thread Kit 1-Insert

Calvan 38900-1 4.6-5.4 & 6.8 Ford Spark Plug Thread Kit 1-Insert image

Product #: CAL 38900-1 DLT


Your Price: $169.99


Brand: CalVan Tools

Calvan Tools 38900-1 is the same kit as the 38900 kit except that it comes with ONE insert. The 38900 spark plug thread repair kit works on many Ford 4.6, 5.4 and 6.8 SOHC Two Valve engines. See below for more details. Or as long as you're making a purchase with us call for assistance in choosing the right kit. Replacement  389-100 inserts are also for sale individually if needed later. This kit uses inserts that are large enough in most cases to do 2nd time repairs when a parts store insert like Heli Coil Save-a-Thread or Dorman (made in China) repair has failed. The 38900 kit is also recommended for 1st time repairs. The inserts have a lip on the top that allow the inserts to be tightened down similar to how a bolt is secured. 

Important - Please Read

Thread locker is not included, but is needed. We prefer High Temp Oil Resistant  Thread Sealer LOC-266 (Seal-Tite). However, some customers choose High Temp  JB Weld 8297. Only one is needed to be used on the exterior threads of the insert when installing to prevent it from backing out on the next plug change. Also recommended is an e-clip used to eliminate the possibility of the thread tap from falling into the cylinder if you tap too far! We've had customers use a paper clip or rubber band in the upper V-Groove of the tap, however the 38900-Clip is the retaining clip that we recommend since it's the most reliable.

We offer Calvan 38900 spark plug thread repair kits with 1 thru 10 inserts. See below. Same kit just a different number of inserts.

38900-1 - Kit with One insert.

38900-2 - Kit with Two inserts.

38900-3 - Kit with Three inserts.

38900-4 - Kit with Four inserts.

38900-5 - Kit with Five inserts.

38900-6 - Kit with Six inserts.

38900-7 - Kit with Seven inserts.

38900-8 - Kit with Eight inserts.

38900-9 - Kit with Nine inserts.

38900-10 - Kit with Ten inserts.

Individual inserts are available later but for the most savings get them in the kit. 

*Bonus-During checkout just write " Tips" in the comment section or mention that you want "tips"  when ordering on the phone and we'll email our exclusive tips. We've compiled over these tips starting back in 2005. That's right we started selling this kit in 2005! *We don't sell on eBay or Amazon - therefore, the FREE TIPS offer is only good at DenLorsTools.com or WiseAutoTools.com.

Calvan 38900-1 Kit Includes:

  • Line up Guide
  • Cylinder Leak Tester
  • Reamer (similar to a drill bit)
  • Tap
  • DVD and written instructions
  • Inserts Quantity - 1
  • Storage Case
  • Emailed tips upon request when purchasing from us.

Make

Model

Engine 4.6

Year  *Exercise Caution

Ford

Crown Victoria

4.6 SOHC 2V

1992 - 2011

Mercury

Grand Marquis

4.6 SOHC 2V

1992 - 2011

Ford

Mustang

4.6 SOHC 2V

1996 - 2004 Excludes Cobra

Ford

Thunderbird

4.6 SOHC 2V

1994 - 1997

Ford

E150

4.6 SOHC 2V

1997 - 2014

Ford

E250

4.6 SOHC 2V

1998 - 2014

Ford

Expedition

4.6 SOHC 2V

1997 - 2004

Ford

Explorer

4.6 SOHC 2V

2002 - 2005

Ford

F150

4.6 SOHC 2V

1997 - 2008

Ford

F150

4.6 VIN W Only

2009  *38900 for 2V's only 

Ford

F150

4.6 3 Valve

2009 *See 39300 Kit

Ford

F250

4.6 SOHC 2V

1997 - 1999

Lincoln

Town Car

4.6 SOHC 2V

1991 - 2011

Mercury

Cougar XR7

4.6 SOHC 2V

1994 - 1997

Mercury

Mountaineer

4.6 SOHC 2V

2002 - 2005

 

Make

Model

Engine 5.4

Year *Exercise Caution                         

Ford

E150/E-Series

5.4 SOHC 2V

1996 - 2016

Ford

F150

5.4 SOHC 2V

1997 - 2003

Ford

F150

5.4 SOHC 2V

2004  *38900 for 2V's only 

Ford

F150

5.4 SOHC 3V

2004 * Some have 3V See 39300

Ford

F250 & F350

5.4 SOHC 2V

1997 - 2004

Ford

Expedition

5.4 SOHC 2V

1996 - 2004

Ford

Excursion

5.4 SOHC 2V

2000 - 2005

Lincoln

Navigator

5.4 SOHC 2V

1998-1999 *38900 2V's only

Lincoln

Navigator

5.4 DOHC 4V

1998-1999 *Some have 4V See 5553

 

Make  

Model    

Engine 6.8 

 Year                          

Ford

Excursion

6.8 SOHC 2V

2000 - 2005

Ford

F250-550, F53

6.8 SOHC 2V

1997 - 2004

Ford

Motorhome

6.8 SOHC 2V

1997-2004

Ford

E350- E450

6.8 SOHC 2V

2014-2016

Calvan Tools 38900, Ford spark plug insert installer is designed to aid in repairing Ford modular cylinder heads on 4.6, 5.4 and 6.8 2-Valve engines (NOT for 3V engines or DOHC).  *38900 is not recommended for holes larger than .678" (17.20mm). This is the O.D. (Outside Diameter) of the reamer in the kit which is 11/16". If the hole is larger than .678" see the  Time Sert 5600 kit which has a larger O.D. reamer which is approximately .73" (18.54mm). See our article for more information on this and other spark plug thread repair kits to fix Ford Spark Plug Blow Outs.

Quality, fool-proof repair system that is fast, cost effective and simple to use.

Used to repair damaged heads from blown spark plugs, with an alloy steel insert, which has no problems with heat transfer or grounding.

Cal 38900-1 Includes one (M14x1.25 Taper Seat) 389-100 thread inserts.

The Calvan alloy steel insert is thicker than most competitive brands which allows for a superior repair even when a Helicoil Save-a-Thread was used previously and failed.

*It's recommended to use a video inspection camera to verify all metal shavings are out of the cylinder before installing the spark plug.

Use the 38900 kit right over the fender without removing the cylinder head. Alternatively, the kit can be used heads that are removed. Many customers decide to do all 8 so there's no future issues. See the demonstration video of the 38900 kit being used on a Romeo style RF1L2E head.

Question - Which is better the Time Sert 5553 or the Calvan 38900? See our FAQ's video below for the answer to this and other questions. 

Over the Fender Repair for 2V 4.6, 5.4 & 6.8 liter engines (excludes InTech, see Time-Sert 5553)

Also works on 2001 and up SOHC engines with the Extra Step Material above the spark plug hole. The Calvan 38900 does not have a counter-bore like the Time Sert 5553 and 5600 to remove the step material before tapping the hole to accept the insert. The Time Sert 55518 counterbore is not designed to be used with the Calvan 38900. That's why TIME-SERT recommends for 2001 and up Romeo heads the 5553 or 5600 to be used since they include a 55518 counterbore. Using the 38900 on 01 and up Romeo heads can result in the spark plug being positioned up a little higher. However, we've had absolutely no problems reported when using the 38900 on 01 and up Romeo style heads. More information on how to identify these 2001 and up Romeo heads can be found in the following article -  Extra Step Material.

Calvan 38900 Spark Plug Thread Repair Video

Calvan's larger outside diameter insert, which is considered a permanent repair is used in cases when smaller parts store temporary repairs have failed. The inferior parts store inserts are supposed to be held in by using a swedge tool on the top of the insert and hitting it with a hammer!

Reduce vehicle down time and added expense by eliminating the need to disassemble the top of the engine to send heads to the machine shop.

With the use of an inspection camera, a quick look into the cylinder after a repair insures there's no metal shavings remaining, prior to installing the spark plug.

This kit comes with a "how to" DVD video (same as YouTube video above). This along with our info, the job can be done quickly and accurately.

* When written instructions are followed also covered in the included "how to" video, there's no faster or better repair available. The cylinder leak tester saves time when making sure the valves are closed. The line-up guide allows for straight reaming even on back cylinders. Use of an air ratchet with a socket on the reamer allows for a 90 degree (right angle) for easier drilling. This makes working in tight spaces more comfortable. The Calvan thread repair inserts have stronger threads than the originals. The cost of the repair is only a fraction of replacement cylinder heads, the head gasket set, coolant, labor, etc. Also, be aware that many re-manufactured cylinder heads have inferior repair inserts like Helicoils or Lisle. If you buy one of those patched heads you could still end up having issues. 

Bookmark or save this page to favorites, it has all the information needed to fix the common Ford spark plug blowout problem, including the instruction video, links to replacement inserts and the FAQ's article.

Using the Calvan 38900 Specialty Tool Kit

It's worth saying again "the Calvan kit has a much thicker insert that can be used when other thinner repairs like the Heli-coil Save-Thread or Lisle have failed to hold". Using the kit requires about the same amount of room as changing the spark plugs. Just a few steps more. The instruction video provides details on using the kit but there are more tips that we have written over the years since we've been selling this kit. These tips are emailed exclusively to our customers upon purchase, just ask us. We'll also personally answer our customer's questions if needed by email or phone, but we've found our written tips, help to clarify the job immensely for those doing this job for the first time.

At checkout just write "Tips" in the Comments section and we will email our exclusive tips for free when processing the order.

Tips - Emailed free after purchase.
Not researched enough? We understand the concern when faced with drilling into your engine. Rest assured this is a proven repair that has been done by many do-it yourselfers and professional techs alike. For even more information see the following page - Calvan 38900 Application and FAQ's or give us a call at 800-524-9783 x251.

Note: We are not responsible for typographical, pictorial or pricing errors. It's our goal to offer the most complete and accurate automotive tool source possible for our customers. We strive to correct errors in listings and provide improved pictures and item descriptions whenever possible. If you question the accuracy of any of our listings please notify us of your concern prior to purchasing.

This spark plug insert kit is designed for in vehicle repair of damaged or missing spark plug threads from ejected spark plugs in Ford 4.6 5.4...

Image 5.0 stars out of 5
F150 Blown Out Spark Plug

Blew my # 4 spark plug out on my 2000 Ford F150 with a 4.6L engine. Made a quick fix from parts store using a $35 kit. Wasted my money, because it lasted maybe a week. Found the 38900 kit here and solved my problem for good. I'd recommend this thread repair kit to anyone!

Reviewed Fri, Sep 25 2015 7:22 am by
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