Vern-MI said: (quoted from post at 15:26:28 02/07/08) The new head is redesigned to eliminate the problem. The change took effect at the begining of the 2005 model year. The new head uses an Autolite HT plug which has plenty of thread and an extended reach. I just changed the plug and the coil on a 2005, 5.4 liter and then was notified by mail that the injectors that year were troublesome and subject to free replacement if any fail up to 10 years or 120,000 miles. I took it in and they replaced the injector free of charge. MIL code indicated left bank rich and cylinder #5 misfire. Runs like a top now.
That is a completely different head, yours is a three valve engine with variable valve timing, his 2001 is a two valve engine with the standard style OHC valvetrain. I don't think the heads are remotely interchangable.
BTW on the 04+ trucks (when they went to the 3 valve engines) the extended reach part of the plug gets corroded can break off in the cylinder head which is almost as bad as them shooting out. Too bad they can't find a happy medium, like they had for almost a 100 years before they messed it all up.
Back the the 2 valve engines, torqueing the plugs to spec is critical when you change them. It seems most of the time when this comes up, they were tightened "about that tight" which is probably either too tight or not tight enough. Too tight and you start to strip the threads outright, not tight enough and the plug works them until they give.
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