spark plug thread repair on Explorer 4.6L

[ab_slack]

Back in October our 2002 Explorer spit out a spark plug. At the time we were able to put a new plug in and it stayed. We figured we were on barrowed time.

Well time has run out, it spit out the plug again from the same cylinder. The threads are entirely gone now.

I think this would be the correct kit to fix the thread but not sure.

http://www.amazon.com/ATD-Tools-5410-Thread-Repair/dp/B00A7EMADE?tag=959media-20

It says for 3 valve 4.6L manufactured before 11-30-07 which I think would cover a 2002 4.6L but then it goes on to say "many 2004-2008 Ford, Lincoln and Mercury". Was there something different prior to 2004?

For what it is worth, this 4.6L is not the original engine, it is a remanufactured engine which was put in a few years ago and listed as being for 2002 Explorer. I don't know if it was listed for other model years. I do know the oil filter it takes is not the one auto parts places list for the 2002 Explorer with 4.6L.

Anyone else have any other suggestions? I seen cheaper kits but this one looks like a more solid product than others I have seen.

Dealer wants some outrageous price, like $580 to fix it.

At shop I trust, he has never done the helicoil fix and says he could try but no guarantees and he doesn't think it is a good fix and seen some fail in short time frames. Long and short of it, the only repair he will do that he says he will back involves replacing the head. More expensive than the dealer.

Another shop I have used says no problem, its no big deal. But at first they seemed to say they never done it but then said yes they have done it plenty of times before. This however is the same shop that due to problems such as ignoring the phasing of the right front axle shaft of my B2 has indirectly pushed me to do more work myself. Having done some hole tapping that a little patience goes a long way toward getting a good quality thread as a result and that rushing it may work but you end up with chewed up threads. I just don't know that I trust this shop to do a quality job.

So once again I am looking at kinda learning by doing this myself. I admit I feel a bit, um tentative about it cause if I mess it up like messing up the new hole, stripping new thread or breaking tool off in engine it might mean having to replace the head. Procedurally after looking thru the instructions I think I can do it.

 

[85_Ranger4x4]

Usually it is the 2v engines that spit plugs and I don't think the 3v engines found their way into explorers until later. They may not have done it on explorers but they have probably done it on trucks where it is more common. As a matter of fact if they haven't done it on a truck run away. An ex will be tighter under the hood and that may be running up their labor calculator.

It may not be the original engine but swapping a 2v for a 3v isn't a casual swap.

Proceed at your own risk, if you bumble it it may cost you a cylinder head.

 

[ab_slack]

Okay, I been doing some reading. You appear to be right, the 2002 should have only a 2 valve engine.

The engine swap should have been a drop in so it should be something close to the original. It does have the 2002 leaky intake manifold problem so its probably the two valve.

So it seems that is the wrong kit.

And after reading I see there are different block types even for the one model year which don't have matching heads so that is another wrinkle.

The one good thing is that it is one of the easy to access cylinders.

 

[ab_slack]

Okay I did some digging.

So for my engine it looks like an ATD 5400 kit instead of the 5410 I linked above. It also doesn't look like quite a good kit and it is more expensive.

I also see Timesert 5553 Kit as the best way to go and that is way more expensive around $410.

Hisses

 

[ab_slack]

I used the Timesert 5553 kit.

There is something distinctly unnatural about drilling into the block, eradicating any spark plug threads and then reaming out the hole larger.

Anyways I found one used from someone who had used two of the 5 inserts and got 40K miles on them and figured they didn't need the kit anymore. I figure I can probably re-sell the used one and recoop most of my money.

From what I found this was the best fix option short of replacing the head (which may have weak threads).

I found options ranging from $30 thru this kit which new was $410. A new head was $400 plus labor so unless I did myself was clost to $1200. Ford wants the better part of $600 and I don't know what their fix involved, but since other than replacing the head the fixes involved a insert that cost less than $20 plus less than a hour of labor I don't see how they get to their price.

Shops around here had various responses but most willing were suggesting a simple helicoil fix which I saw lots of comments about how unreliable.

So far it is working okay. Time will tell but since I am feeling optimistic.

 

[Sasquatch_Ryda]

The Timesert is what we use.