Subject:
Date:     12/23/2004

It appears that Ford Expeditions, particularly the 1998 model, have an
engineering flaw regarding the spark plug on the passenger side of the
5.4 liter motor. Recently, we experienced the same fate as others have
described in regard to the spark plug being blown out of the head when
the engine was running. After contacting a local Ford dealership, I was
told there were no recalls regarding this problem, although they have
repaired several vehicles with the same defect.

Likewise, after speaking with an independent mechanic, I learned that
he has also repaired several Expeditions with the same problem on the
passenger bank of the engine. In his words, "this motor is junk."
Additionally, he told me that the flaw in that particular spark plug
hole deals with the lack of threads in the head. He said he is unsure
as to why the machining in that area would not allow for more threads
in that spark plug hole. This seems to be the root of the entire defect.

When I inquired of Ford as to the cost of repair, they were unable to
give an exact amount. I was told that it would entail removing the head
to repair the damage. I am concerned about this approach because the
heads on this vehicle are aluminum, which could create another problem,
e.g., milling the head can increase the compression, and therefore,
increase the heat and change the tolerances in relation to the valve
and piston clearance in that side of the engine. As of this date, my car
is still incapacitated, and taking it to the dealership is out of the
question!