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Old 03-05-2013, 16:43   #1 (permalink)
DJT
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MAJOR UNDERTAKING

Hey all, I have the notorious 03 expedition with the 16 valve 5.4 liter P.O.C.
About a year ago (80K) my truck spit out a spark plug. Took it to the dealer because they had good news. They said it was so common that ford makes a repair kit that doesn't require removal of the head. Well now because they did a crap job the same plug blew out again, this time the insert came out with it. So now I have to actually replace the head. So I started looking around trying to find someone that has an aftermarket head without the screw up that ford made (three friggin threads holding the plug in). Thank you Lord! I hit the jackpot! Found heads that have a full sleeve, they are going to install over sized valves and performance cam, without completely breaking the bank. 550 ea. so the only way I can afford this ordeal is to do the work myself. Being active duty military with a newborn and a stay at home wife things are a little tight. anyway, I was hoping someone out there would be able to throw me a bone with some tips and/or tricks from experience. Maybe even some DOs and DONTs. Thanks in advance, I'll keep ya'll updated on the progress. WISH ME LUCK!
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Old 03-05-2013, 17:11   #2 (permalink)
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Re: MAJOR UNDERTAKING

First and foremost, thank you for your service.

Found a video on the head replacement, but if you're going to be doing a lot of your own work, you might consider a subscription to AllData DIY. They'll give you step by step on your major mechanicals as well as a lot of information that doesn't get covered in Auto Zones self help.

5.4 Lincoln Navigator cylinder head removal - YouTube
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Old 03-05-2013, 18:27   #3 (permalink)
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Re: MAJOR UNDERTAKING

Thank you for your support!

I followed the link you sent and watched a couple of videos. I definitely feel like I have more of an idea of what to expect. Looks like the Lincoln has a heck of a lot more room in there than my truck. He didn't even mention taking the whole engine out. So far everywhere I have looked it either says to lift off the body or to pull the whole engine. Any knowledge on that topic? Again thank you so much.
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Old 03-07-2013, 16:56   #4 (permalink)
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Re: MAJOR UNDERTAKING

You might have an accessibility issue in the Expedition that the Lincoln doesn't have (thought they were the same vehicle). Not sure how much room you have above the engine, but often you can block up the engine rather than pull it.

What you do is jack up the front end, block up the engine and unbolt it from the mounts, then lower the body. Depending on the geography of your engine, you might be able to remove the mounts and raise the body high enough to gain better access from below.

Don't know how things set in you r engine bay, but if it's anything like the vans, I don't envy you.
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Old 03-08-2013, 08:05   #5 (permalink)
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Re: MAJOR UNDERTAKING

Thank you for that, actually hadn't thought of that. Once I remove intake manifold and the valve covers and everything else up there, there just might be room for that. Really appreciate the idea. I'm actually breaking ground on it today.

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Old 03-08-2013, 13:02   #6 (permalink)
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Re: MAJOR UNDERTAKING

Good luck!
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Old 03-11-2013, 05:40   #7 (permalink)
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Re: MAJOR UNDERTAKING

I took your advice and purchased the subscription to the alldatadiy website. Definitely helpful, and it was the same price as the paper manual. So far I have the whole intake removed. I haven’t had a ton of time to work on it, this weekend my 6 month old, my wife and I were all sick. I’m going to get back at it every day this week after work. BTW do you know anything about taking the intake manifold apart? Now that I have it out I was thinking about cleaning it thoroughly. Any reason I shouldn't do that? Thanks again for your advice.
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Old 03-12-2013, 17:48   #8 (permalink)
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Re: MAJOR UNDERTAKING

My advice is this, if you have it open, take care of it. It's easier to clean it when you can turn it over, etc., rather than when it's bolted in on top of your block.
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Old 03-13-2013, 13:01   #9 (permalink)
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Re: MAJOR UNDERTAKING

Thats what I figured, I'M GUNNA MAKE HER SHINE!!! I'm also planning on painting and polishing here and there while I have her apart. She's going to pretty awesome when I'm done.
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