If you’ve ever owned a vehicle from Ford between the years 2004 to 2008, you might also be familiar with their infamous spark plug disaster during that time. From the spark plugs getting jammed in place, breaking upon removal, and of course, blowing out abruptly, every mishap was a possibility.
But did the well-known motor company ever resolve this issue? If so, what year did Ford fix the spark plug problem, after all? We’ve taken a deep dive into Ford’s faulty spark plug history to bring you the following rundown of the notorious mishap that impacted millions of drivers.
Let’s start right from when the problem first arose.
Which Year Did Ford Fix the Spark Plug Problem
While many people believe that Ford had fixed their spark plug problem in 2003, it is still argued whether this issue is really “fixed” at all.
Even though the company said that this was not the vehicle owner’s fault, they still did not act upon a widespread or official Ford spark plug blowout recall.
Some lucky drivers, however, had been covered by Ford’s New Vehicle Limited Warranty. Because of this, they had damaged parts such as cylinder heads replaced without cost.
But this warranty did not do anything for spark plugs or cover repair costs.
Even today, it’s best to avoid models from Ford produced during the problematic years to dodge spark plug problems.
When considering a vehicle model, these are the “problematic years” you should be cautious of –
- Late 2003
- 2006 to 2008 (modular engines)
Modular Engines with Spark Plug Issues to Avoid
The Ford spark plug issue was still evident around the years 1997 to 2003. Ford had experienced an increasing number of drivers facing issues with their modular engines from vehicle models produced between 2004 to 2008.
These modular engines from Ford come in various types, including –
- 4.6 liters
- 5.0 liters
- 5.2 liters
- 5.4 liters
- 6.8 liters
The 5.4L and 6.8L vary only by cylinder count (V8 and V10, respectively). Also, these engines can be either of aluminum or cast-iron block. They have valves ranging from 2, 3, or 4. All these models came out during the problematic years.
Despite their variety, they all have one thing in common: faulty spark plugs.
Common Problems with Ford’s Faulty Spark Plugs
Because of Ford’s wide range of model types and fast production, the spark plug issues faced by drivers varied around the US.
The most common issues with the spark plugs were –
- Constantly blowing out
- Threads breaking off during removal
- Prone to damage beyond repair
- Being stuck in place due to missing or stripped threads
It’s a popular belief that Ford had fixed the spark plug problems in its V10 engines in 2003.
To be on the safe side, the Ford V10 years to avoid would be from the years 1997 to 2004 or 2008, depending on how much the warranty will cover for you.
The known Ford 4.6 spark plug problem years are between 2004 – 2008, especially the V8, 3-valve versions, and F-150 models.
As the 5.4L engines were built in 2004, it caused issues in models from 2004 – 2006, but by 2007/2008 it was said to have been repaired by Ford.
So, what year did Ford fix the spark plug problem? Having said all that, even though the majority answers 2003, we believe it’s best to avoid engines produced during the problem years and go for a newer and improved build.
While newer models might not be to your taste or fit your budget, they will save you the hassle of spending a fortune on repairs without a warranty to stand behind.
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I am Todd Hicks, a classically trained automotive expert with a vast knowledge of autos. I own an automotive workshop in the United States. In this field, I have 20 years of experience. I’m particularly interested in sharing vehicle tips and tricks with car-dedicated people. Writing is equally fascinating to me as a technique of sharing my thoughts.