Why did a spark plug blow out of my Ford Excursion V10?

Short answer: The 6.8L V10 in the Excursion has few threads holding each plug in the aluminum head. Plugs can loosen and blow out, stripping the threads. Owners repair them with thread insert kits. Cheaper kits failed for some owners; stronger ones held for tens of thousands of miles.

Symptom: A loud ticking or popping sound, misfire, check engine light, or a plug and coil sitting loose.

What to check first

1. Stop and look for a loose coil or plug.
2. Don't keep driving on a blown-out plug.
3. Ask about a thread insert like a Time-Sert.
4. Check the other plugs' torque.

Likely causes

1. Stripped plug threads in the head.
2. Plug not tightened right.

What it usually costs

Owners said permanent insert kits cost $250–$450, and a shop repair with a tow was about $1,000.

Is it safe to keep driving?

No. A blown-out plug can damage the coil and wiring and harm the head. Verify with a mechanic.

DIY or shop?

DIY for experienced owners. Use a quality kit. Change plugs every 50,000 miles and torque them to spec (an owner listed 25 ft-lb).

Recalls, bulletins and complaints in plain words

• Recalls: NHTSA lists no recall for spark plug blowout on the Ford Excursion for these model years (checked 2026-10-22). Other recalls may exist for your car, so check your VIN at nhtsa.gov/recalls. If your car is part of a recall, the dealer fixes it for free.
• NHTSA complaints: 203 keyword-matched complaints for Ford Excursion 2000–2005 (of 1,216 unique complaints queried, NHTSA complaints API by model year, queried 2026-10-22; keywords: spark plug, plug, blew, blown, ejected, misfire, thread). This counts complaints that mention these words. It is not a defect finding.

What owners report

• In this Ford-Trucks thread, an owner's cheap repair kit kept failing. Members recommended Time-Sert type kits at $250–$450 and said a shop job with a tow ran about $1,000.
• In this Ford-Trucks thread, a 2005 owner's insert kit held 20,000 miles, while a Time-Sert repair lasted over 50,000. Members said to change plugs every 50,000 miles and torque to 25 ft-lb.

Quick tip

Pay for the good insert kit. Doing it twice costs more.

Vehicle focus: 2000–2005 Ford Excursion with the 6.8L V10.

Safety / mechanic note

A blown-out plug can start a fire near fuel lines or damage the engine. Verify with a mechanic.