I have a 2001 ford f350 and one day after coming out of the gas station i heard a loud pop after starting my truck. upon inspection i found that i had blown out one of the plugs. the gap was completely closed and it had worked its way out untill it just popped the rest of the way. after i waited to get the tools and parts from people there i put the new plug in with no problem at all, it went in just as any normal plug would have. i then drove over 500 miles back home with it and it wasnt untill i went the change the other plugs that my "Problem" has occured. i went back to the hole where the plug had popped out to check and make sure there wasnt anything wrong with the cylinder, and there wasnt, its fine but now i cant get the plug back in at all. i have tried everything from new plugs to the old plugs. ive gotten a 14mm chaser down in the threads just fine no problem at all. ive also gotten a 14mm 1.25 tap in there just fine as well. i know that the threads are okay enough to get the chaser and the tap in there so why cant i get a plug down there? any ideas? i appreciate any help i get as i have been at a loss of them since starting this.

 

i know about time-sert and helicoil i just dont want to go that if at all possible.

 

I have heard a lot of horror stories about the 5.4 and 4.6's blowing out plugs - yuck! What did the original plug look like when it blew out? There had to be some damage for it to shoot out of the hole. How are you trying to put the new plug in - with a socket? Is it possible something is in the way of the tool your using and not the plug? I always start spark plugs with some fuel line to avoid cross threading them. Good Luck!

 

other than the gap being closed the plug showed no other signs other than normal wear and tear. ive been using just a 5/8's socket with the extension, i even used a garden hose still no luck