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Old 01-17-2011, 17:33   #1 (permalink)
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2003 Expedition Running Rough after Spark plug Blow Out

I have a 2003 Expedition, 5.4L. I just recently experience the infamous spark plug blow out problem at about 111,000 miles. I purchased the kit to repair/install new spark plug, replaced the coil, and now the vehicles idles fine, but when accelerating, it runs rough as if it is mis-firing? Any ideas or help with this is greatly appreciated. I am hoping there is not something more serious with the motor that may have happened when the spark plug blew.
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Old 01-17-2011, 17:48   #2 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

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Originally Posted by vqjd73 View Post
I have a 2003 Expedition, 5.4L. I just recently experience the infamous spark plug blow out problem at about 111,000 miles. I purchased the kit to repair/install new spark plug, replaced the coil, and now the vehicles idles fine, but when accelerating, it runs rough as if it is mis-firing? Any ideas or help with this is greatly appreciated. I am hoping there is not something more serious with the motor that may have happened when the spark plug blew.
Did you Gap this Plug to Specs?? and Check the Wire??
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Old 01-17-2011, 17:53   #3 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

Take it to Autozone and they'll pull codes for free.
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Old 01-17-2011, 18:27   #4 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

Thanks for the responses!

Sterling_six--The guy at the auto store said it was pre-gapped (spark plug came with the repair kit)

Bert-Will it still throw a code even though there is no check engine or other warning light on?
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Old 01-17-2011, 18:39   #5 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

Check to see if you have the Plug Wire fully connected to the tip of the Plug...I personnaly never trust "Pre-Gaped" Plugs...But did you happen to see the Gap Range on the box?
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Old 01-17-2011, 18:55   #6 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

There can be codes without the light.
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Old 01-18-2011, 01:32   #7 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

I ran into this once, and the fix was simple for me. I simply had accidentally dislocated the spring in the coil when I pulled it off. So when I installed the same coil back on, it wasnt actually making connection. So my preventative for that now is just to simply disassemble coil boots and springs from the coil itself and reassemble. It also gives me a chance to inspect them. But, if this is not your problem, try individually unplugging coils to see if any one of them isnt affected when you unplug it. If the cylinder you just worked on isnt affected, then you need to either reconsider the work you did, or test the coil.
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Old 09-14-2011, 07:26   #8 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

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Originally Posted by vqjd73 View Post
I have a 2003 Expedition, 5.4L. I just recently experience the infamous spark plug blow out problem at about 111,000 miles. I purchased the kit to repair/install new spark plug, replaced the coil, and now the vehicles idles fine, but when accelerating, it runs rough as if it is mis-firing? Any ideas or help with this is greatly appreciated. I am hoping there is not something more serious with the motor that may have happened when the spark plug blew.
Were you ables to resolve this problem? If so, I would appreciate if you could tell me how.
I have the same issue since I had my spark plugs replaced, and it's getting worse. And no codes are showing up at all.
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Old 09-14-2011, 17:16   #9 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

There could be a spark plug boot dried and cracked.
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Old 10-05-2011, 09:07   #10 (permalink)
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Re: 2003 Expedition Running Rough after Spark plug Blow Out

Unfortunately you may continue to have this problem. From my experience with this aweful engine, once one coil blows the rest will fall like dominos. I was told to be prepared to fix them all at some point. Ford really messed up with this design and should be held responsible.
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