Wow! How many words are limited here? A previously wound spark plug burned out in my 2010 F150 4.6. And of course it's a construction truck - I don't have time for it to fail! No truck, no income! I considered replacing the head with a rebuild, but barely succeeded, and then I thought of a remanufactured or new motor in a box (it has 208,000 miles). All of this has led to a lot of research in search of a solution. Fact: Although there are many threads on the connector itself, Ford only uses 4.5 of them! And pulls them up to 12 ftlbs! No wonder so many people pop the cork! Spiral coils are generally an effective fix, won't work here as they only engage a few turns and don't have head material to engage the locking mechanism. Calvan, a longtime automotive tool maker, has developed a complete repair kit that allows you to ream old threads, rethread threads to a larger diameter, and install a stainless steel insert that uses about an inch of thread to hold it in place. Total install time? About an hour for the first (which included a phone call to a great Southern California guy who does nothing but fix things and can offer specific additional advice - check it out on YouTube) and 25 minutes for the second. 3/8 high torque pneumatic ratchet; Of course, some car knowledge, a feel for tools and some machining experience are helpful - you can't be clumsy with that! The cost for a kit that does 8 holes, about $275, is very reasonable considering the cost of other routes, and it's machinist quality. What a lifesaver! Now under repair 5k.
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