britincali

I launched the 3rd plug back on the pass side last week and decided instead of waiting 2 weeks for ford to fix it I was just going to put an insert in.

I got the info for the kit here :- http://www.timesert.com/html/howtosp.html

And ordered it here :- http://www.threadkits.com/

I got kit # 4412e with insert #s 44185 and 44186, one is slightly longer than the other and I was told by different people to use different ones so I just ordered both! It turns out 44186 was pretty much perfect and 44185 as a little short. Total cost came to just under $150 shipped.

Heres is part of the kit and the inserts :-



I used an old head from a blown motor so I could get some decent pics and some practice before I tried it on my baby.

britincali

Here is the reason for all the problems in the beginning, what was ford thinking???



4.5 measly alloy threads!


First librally coat the tap flutes in grease to catch all the shavings...



Then insert into stripped plug hole...



Add the extension to the end and either use the supplied bar or if needed a 1/2 " socket and a swivel...



Tap the hole, I did roughly 3 turns at a time, removing the tap and cleaning off the shaving inbetween the flutes...



Continue until the tap is almost flush with the head...



Underside...



After the tap is all done cutting and little resistance is felt its time to cut a new seat for the plug using this tool supplied in the kit...



With the tap in place slide the seat cutter over it....



And cut away, I did roughly 4 full turns I could have done more but didnt want to go overboard and screw something up..

britincali

Now its time for the insert....



Coat the end of the insert driver in oil...



Then thread the insert onto the end and add threadlocker (I used red permatex hi-temp)





Then thread in the insert, after 5 or so turns you will feel resistance as it cold forms the last 2 threads in the insert, continue untill there is no resistance and remove...



I now have at least one cylinder with more than 4 threads!!!

britincali

The job is a harder on the truck due to tight places and having to use extensions, it took me 20 mins with the head off being really careful and taking pics, and about 45 mins on the truck.



I JB welded my coilpack back together and re-installed it.



Doing this off the truck I noticed that if you do it slow and removing the tap and cleaning repeatedly no shavings drop into the cylinder, I just re-installed the plug and coilpack and she fired up. To do this perfectly I would use a shop vac with some small hose duck taped to the end and vacuume out the cyl.

She fire right away and after 10-15 second of missing ( Im thinking grease got in the cyl) she cleared right up and running 100%.


IMO this is a way better fix than replacing the head with the same 4 thread one that came off (and thats what ford does they dont even upgrade you to the newer ones when under warranty)

britincali

Here is the finished product, I purposely overtorqued the plug to see if the insert would spin or strip, I leaned on it way harder than I ever would on the motor and it was all good.

fepony

Looks like the plug is indexed pretty well too. Did you do that on purpose?

britincali

Nope just happened that way, happy thanksgiving fep!

HDSouthCali

nice write-up.... glad you got her up and running again...

tpr103

its about time somebody did on H/T on this!!

Dbl G

Great Job Chris, One may add that you should before the thread lock sets. Index your plug this a perfect time.
Indexing is making sure the open gap is facing center of the cylinder such as in Chris awesome photos above.
I also recommend removing the head. This is a pain however it does lessen (100%) the chance of having a shaving or two fall into the chamber.
What would that do?
It will melt and stick to the piston top and create a hot spot,,,not good at all.

britincali

Or migrate to the cylinder wall, catch on the ring, and then smear all over the piston and barrel worst case scenario melting a piston.

Im hoping any shavings I may have had went straight out the exhaust valve!

Tazz

OK indexing when doing time serts seems really easy.
? can indexing be done on a traditional head when on/ off the engine?
Guess they can. I wasn't sure with the tapered seats.
Tazz

Dbl G

http://store.summitracing.com/egnsea...12&D=%2D113312

http://store.summitracing.com/egnsea...40&D=%2D113040

Yes one can index with the heads on, simply mark the location of the electrode on the top side of the plug and add washers until it lines up centered..