When Do Technicians Use A Thread Repair Insert

The Fourth dimension-Sert 5600 has the largest exterior bore insert available which tin can be used when previous repairs accept made the hole and then big that the Calvan 38900 cannot work. The Fourth dimension Sert 5600 spark plug thread repair kit as well works for more applications than the Calvan 38900 does. Nosotros have the "How to" video (below) that demonstrates how to use the largest kit bachelor (Time Sert 5600) to finally set the dreaded "echo" diddled out spark plug trouble that has left the pigsty too big to fix for regular kits.

We've sold many of these spark plug thread repair kits, saving Ford owners a lot of time - and money in the process. In the following article we'll explain why this should be the side by side and concluding "over the fender" repair (fifty-fifty in vans) purchased for this particular application. Again we can help with choosing the correct kit, but below is a bones guideline for Ford 4.6, 5.4 & half-dozen.8 engines that use M14x1.25 spark plugs.

Time Sert 5553 - Repairs spark plug holes smaller than .663" (xvi.8mm). The outside diameter of the insert is .69"- it's Double Over-sized, used on many applications and has a Triton counter-bore needed for some 2001 and up. *Annotation Addition Kit 5588 for repairing holes larger than .663" (16.8mm) repairing holes upwards to .73". Works for SOHC and DOHC engines. This kit is Made in the The states.

Time Sert 5600 - Stand up Lonely Kit that repairs spark plug holes larger than .663" (16.8mm). The exterior bore of the largest insert is .77" - it's Triple Oversized. Used on many applications and has a Triton counter-bore needed for some 2001 and upward.*Note Addition Kit for installing the Double Over-sized inserts for holes smaller than .663" (sixteen.8mm) is kit number - 5588. Works for SOHC and DOHC engines. This kit is Made in the The states.

Calvan 38900- Over sized kit that repairs spark plug holes up to approximately .678" (17.24mm) which is the reamer O.D. The outside diameter of the insert is .73". Due to the guide existence required this kit has a limited awarding (compared to Time Sert ). Fits simply Ford SOHC 4.6, 5.4 and six.8 engines from around 1996 to 2003 (some models upwards to 2016). See our Calvan 38900 listing for more application details. Since there's no counter-bore for certain engines from 2001 and up for this brand, Time Sert recommends their kits, although we have not heard of any issues when using the 38900 kit. The 38900 works for just certain SOHC engines. This kit is made with some USA parts & Globally sourced components.

Note that some 2004-08 3V engines apply a different kit for M16x1.25 - Calvan 39300 or Time-Sert 3221 DLT. The Calvan 38900 DLT is for Triton engines from 1998-2003 (some models upward to 2016), if working on a DOHC InTech engine, use Time-Sert 5553 or 5600. If working on a 2004-08 3V engine with M16x1.5 spark plugs use the Calvan 39300 or the Time-SERT 3221. Some 2008'southward and newer apply 4212H for M12x1.25 Spark Plugs. The 4212H also works on newer Ford's that use the M12x1.25 spark plugs including some Ford Escape and Ford Fusion with i.five Liter engines. Make sure M12x1.25 is the plug size. If it'due south a a one.half dozen it volition exist different.
Ford Spark Plug Blow Out Repair Kit Info

Ford blown out spark plugs is a mutual problem with engines in Ford F150 pick up trucks, Mustangs, Crown Victoria'south, Vans, Expeditions and motor homes. A video showing spark plug thread repair using Calvan spark plug inserts being installed can be viewed on the Calvan 38900 clarification folio. Read on for more information.

Ford 4.six, five.4 and vi.eight modular engines are decumbent to spark plugs being blown out of the cylinders due to the aluminum threads failing. When the threads are nearly to come loose there is often a slight ticking sound/noise, like a small "exhaust manifold leak" would sound.

When the spark plug threads neglect, information technology can squirt the spark plug and break the ignition coil on the "gyre over spark plug" design. Although rare, information technology is possible an engine compartment burn can erupt due to the raw fuel escaping the engine cylinder and the broken curl dangling, providing the spark. The cause of failure of the spark plug threads tin can exist debated; poor design, over-torqueing, under-tightening can permit the spark plug to vibrate and article of clothing threads while held in past the coil, until the threads deteriorate and eventually fail. We have many Ford dealers that utilise Fourth dimension Sert and Calvan, however there are some Ford dealers that will non recommend repairing the threads. Many only recommend replacing the cylinder caput. Considering of the expense of labor and parts involved in replacing the heads we recommend using the appropriate thread repair kit made past Time Sert or Calvan. Later this repair the threads will be stronger than original.

Below is some other reason we recommend using the over the fender repair every bit opposed to removing the heads.

Gaining access to the cylinder caput bolts and removing the heads is difficult on trucks and SUV's. To remove and re-torque the heads, nearly Ford technicians do a "cab off" or "torso off" performance. On trucks the cab is unbolted from the frame; on SUV's and vans the entire body is unbolted from the frame, the electrical wiring, AC lines, radiator hoses, heater hoses, chief cylinder, etc. are disconnected. This allows the tech to utilise the car lift to raise the cab or body off of the frame. Once this is washed the engine can be serviced much easier. This procedure takes less fourth dimension than you might expect afterward the tech has done a few of these and knows exactly what needs to exist done. However, using one of our kits and eliminating the need to do all that extra work is plainly the most cost constructive method.

Below explains the difference between HeliCoil and the Time Sert and Calvan blazon insert.

Many techs at car repair shops will employ a Heli-ringlet repair kit to install a new Heli-scroll insert. Techs are familiar with HeliCoils that are good for many applications. The proper noun HeliCoil is used every bit a generic proper noun for a thread insert. This is similar to how some people say "Kleenex" merely they are really using the term as a generic term for facial tissue. Just to clarify though; The Time Sert and Calvan blazon inserts are Not the same as the Heli Scroll. The Time Sert and the Calvan inserts are much thicker and much stronger and volition not leak compression. They too last the life of the vehicle. That existence said, I actually have used the Heli-coil (wire coil) repair kit on two unlike occasions (years before I started selling tools) and neither of them failed that I am aware of. Sometimes they fail when the spark plug is removed on the next plug change. One business organization of using the Heli-ringlet is that combustion pressure may escape the cylinder since the spark plug may not seat perfectly. I am too aware of a very experienced tech (likewise an ASE Primary Tech) I used to piece of work with, that installed a Heli-gyre. However it did fail inside a week subsequently it'due south installation. The cylinder caput was removed and sent to the auto shop, subsequently it was deemed equally "not repairable" by the motorcar shop. If we would take simply known about the Time Sert and Calvan repair kits back then, the cylinder could take been saved. This is because the Fourth dimension Sert and Calvan inserts are much thicker and are large plenty to repair a spark plug hole that has had a Helicoil fail previously. In fact, we commonly sell to customers that have had a Heli-Coil repair neglect and blow back out. We as well have had many customers that have tried cheap parts store kits that only bought them a lilliputian time, earlier they were dorsum in the same situation, with a Blown spark plug.

Dorman 42025 HELP

The Dorman China (and Mexico more recently) made DIY kit that parts stores have been selling a lot. They accept been keeping us VERY busy. It'southward what we consider a temporary repair because it relies on a self tapping adapter and uses a Ford 3V spark plug! Sometimes they last a footling while, sometimes they leak compression and sometimes won't even thread in at all. Nosotros sell the Time Sert 5600 and Calvan 38900 Combo Kit when the Dorman fails. If compression leaks outside of the exterior threads on the Dorman insert/adapter, the hole in the caput tin get oblong. Then information technology'southward best NOT to drive a vehicle that's losing compression. 1 recent client used the Heli Gyre Save-A-Thread kit and it lasted iii months. He and then used a Dorman HELP kit and it lasted a calendar week. In this example information technology didn't blowout. The rut that resulted from escaping compression melted down the spark plug kick and some hoses. What a disaster! The Dorman cocky threading sert originally was made in China and most commonly would blow out afterwards awhile making the hole bigger. Dorman changed their manufacturing location to Mexico most recently and now the trouble is they interruption in One-half. This is a new trouble. Our kits are designed to drill out aluminum; Non hardened steel. Therefore the broken piece has to exist removed earlier using i of our kits. Some customers take been able to utilize the German language made Double Border Extractor kit to remove the broken Dorman piece earlier repair the threads with one of our kits.

More on repairing damage from the Dorman... Fourth dimension Sert kits are designed to drill out the bad textile and to tap threads into the hole, to accept the new solid insert. The Time Sert installation commuter, finishes the threads and expands the lesser of the insert locking information technology into position. So if you need aid subsequently using the Dorman HELP kit, we got you covered! Encounter our second website for more info on the China fabricated Dorman Cylinder Head Repair. Or give us a call at 800-524-9783.

DenLors Tools and sister site WiseAutoTools.com has sold thousands of dollars worth of Time Sert and Calvan kits since 2005. The kit numbers listed on this folio are continually our all-time sellers and we've had no reported failures! 1 of the all-time features is that the spark plug thread repair inserts can exist installed over the fender without the need to remove the cylinder head.

Using the Time Sert or the Calvan Kits
It's worth proverb once more "these kits have much thicker inserts that tin be used when other thinner repairs like the Heli-gyre or Sav-A-Thread have failed to hold". Using these kits require most the aforementioned access as if you lot were changing the spark plugs. Only a few steps more. The educational activity videos that we provide, layout details on using the kits. Upon request when purchasing from the states, we provide a compilation of the tips nosotros retrieve are important when using these kits. These tips are emailed to our customers upon buy. We will also personally answer questions if needed, simply we've institute the tips clarify the job.

At checkout just write "Tips" in the Comments field and we will e-mail the tips when processing the gild.

Boosted Tips

Emailed gratis after buy. Only write "Tips" in the comments during checkout.

Time Sert products are proudly made in the The states - Reno Nevada. Horizon Tools (Northward Carolina) provides u.s.a. with the Calvan Kit, besides sold as Mount9200 and other labels including Blue Betoken (sold by Snappy for about twice the price). Many of our customers with 4.6 or 5.4 or 6.8 engines, determine to put inserts in all cylinders. Some only fix the failed ones and bank check the tightness on the others. Either manner, this helps prevent the possibility of any future spark plug accident-outs.

Basic Tool List

1. Standard Pliers (not included) 5/8" Spark Plug Socket (not included)
2. 3/viii" Bulldoze Extensions (not included)

iii. Inspection Scope/Photographic camera (not included) - Use to cheque for metal in cylinder.
iv. Air Ratchet (not included) If a expert quality air ratchet is non on hand we tin can ship one at the same fourth dimension.

5. Starter Button-optional (non included) Manually turning the engine with a socket and ratchet on the crank commodities eliminates the demand for a starter button.
6. Cylinder Leak Detector (included in 38900 kit) Available separately.

7. Air Accident Gun with viii-12" of Minor Tubing (non included)
viii. Safety Glasses (not included)

Lubrication similar Atomic number 82 Blaster or WD40 (not included)
nine. JB Weld (non included) Loctite is included in the Fourth dimension Sert kits

10. iii/8" Ratchet (non included)
eleven. Shop Towels (not included)

12. Air Compressor (not included)

13. Restriction Cleaner, to assistance clean out the cylinders and provide clean threads for loctite or JB Weld to attach to.

Below are a few of the questions we accept answered related to spark plug blow outs in Ford and Lincoln vehicles. Run into our mechanics FAQ tool web log for even more questions answered on this topic.

Question: I have a 1999 Ford F150 with a 4.6 liter Triton engine with 126,000 miles on it. The number 3 spark plug blew out of the cylinder caput. I called my local repair store and was told that this was a mutual problem with this design engine because of the extremely sparse (aluminum) casting in the spark plug expanse of the engine caput, there is only almost five threads for a spark plug. How are your inserts better?

Answer: While it is truthful there are merely five threads for the spark plug in this pattern engine for the spark plug and the Calvan insert has five spark plug threads as well, the Calvan spark plug insert is steel not aluminum and the insert itself is held in place with ten external threads. The Calvan spark plug insert improves the blueprint and durability at fraction of the price of replacing the cylinder heads with the same design weakness. Time Sert offers fully threaded inserts PN 51457.

Question: I am selling my truck equally fast every bit I can go a spark plug to stay in long plenty to get rid of information technology. I wanted to use a Heli-roll because I won't have to drill, but the thread tool isn't long plenty to reach in the spark plug recess, any suggestions?

Respond: I personally recommend the Fourth dimension Sert or the Calvan tools because they are a better repair, but if you would rather use the thinner Heli-whorl insert, the HEL5396-14 has the longer thread tool than the standard Heli-coil kit.

Question: I have Ford van that has had a Sav-A-Thread installed previously, information technology has blown out and I desire to know if the Calvan insert will piece of work since the Sav-A-Thread has left a bigger hole now?

Reply: Yes, the Calvan spark plug repair insert is a larger insert and has worked well for our customers before, saving the expense of replacing the heads. The Fourth dimension Sert 5600 has the largest outside diameter and therefore can salve heads that have pretty big holes. In fact up to .73".

Question: I used a Dorman 42025 cylinder head repair kit on my 2001 Ford F250. I hear compression leaking though. Exercise you have a thread repair kit that tin fix an egg shaped hole?

Answer: Aye. The compression is most likely leaking from around the outside of the Dorman spark plug adapter (insert). The Time Sert 5600 kit (Designed and manufactured in the USA) fixes holes up to nearly three/4" wide. The reamer removes the bad material, leaving nice round hole to work on. Then a thread tap threads the hole to accept a triple oversize insert. It's installed with an installation driver which finishes the bottom threads and expands the bottom, locking information technology into place. Then a smaller insert goes into that and so the original size M14x1.25 spark plug can exist used. This is what nosotros telephone call a permanent repair as opposed to the Dorman Assist kit, which we consider temporary based upon the reports nosotros get from our customers.

Question: I bought a rebuilt head and come to find out one spark plug holes had a repair insert, information technology blew out last calendar week. The cylinder head has a warranty, but I cannot beget the downward time all over again. Volition the Time Sert or Calvan insert repair this hole?

Reply: Yes, the Fourth dimension Sert or the Calvan inserts, both take thicker beefier repair inserts that you don't have to worry almost. And I always tell our customers that when purchasing a rebuilt head of this blazon to be aware of the possibility that inferior repair inserts may already be in the head. Ownership a make new head would insure that at that place are no cheap inserts, simply you would be stuck with the original weak design. Either the Time Sert or the Calvan thread inserts will save down fourth dimension, money and are stronger due to the material beingness steel blend instead of aluminum like the original threads.

Related Repair Articles and Specialty Tools

TIME-SERT 5553 - Ford Spark Plug Repair Kit - PN 5553 for DOHC InTech engines and many other Ford applications when used with the proper insert.

Time Sert 5600 - The Largest - Stand Alone Triple Oversized Thread Repair

Calvan 38900 Ford Spark Plug Insert Kit - for Triton SOHC 1998-2016 with M14x1.25 Taper Seat Plugs. Replacement insert number is 389-100.

Blowout FAQ'due south Recommended Reading for Using CAL38900 - Your question may be answered in this web log. Nosotros've compiled a ton of questions we've had on this job since 2005.

Expedition Cylinder Head Removal � Body Off - *Removing the body is NOT required for employ of the Time Sert or Calvan thread repair kits. Merely run into what you're missing!

Video Inspection Cameras - Not all techs utilize them, but to assistance verify metallic shavings are removed after drilling tapping etc.

Air Ratchets - A skilful quality air ratchet is recommended past Calvan for drilling, using the bit in the 38900 kit.

TIME-SERT 3221 - for nearly 2004-2008 3 Valve engines with 16x1.5mm threads.

Calvan 39300 - likewise for virtually 2004-2008 iii Valve engines with 16x1.5mm threads.

Below Covers 04 & upwards Dissimilar Ford Spark Plug Problems - 3V Broken Spark Plugs & Porcelain Staying In

Question: I accept an 05 Ford F150 with a v.4 liter engine that has a spark plug broken and I can't remove the broken piece because the office that the spark plug socket goes on came out. I know this is a completely different trouble than threads missing, simply do you know how I can remove the cleaved spark plug without removing the head?

Answer: Y'all are right this is a totally different issue, but you're non alone. What we used to sell for this trouble was a spark plug remover, a specialty tool fabricated by Rotunda, the number is 303-1203. Nosotros apply to sell a lot of the 303-1203 special service kits, but at present the LIS 65600 is what we sell the most of for removing Ford cleaved spark plugs. See the LIS 65600 DLT in utilize tool weblog for more data.

Question: I'm looking for Ford Rotunda OTC tool number 303-1398 for removing the ceramic or porcelain role of the spark plug. Thanks, David

Answer: The Rotunda 303-1398 and 303-1203 are pictured above, they are expensive Rotunda specialty tools. Calvan has low cost alternatives and the tool number are CAL39100 & CAL39200. The porcelain extractor tool kit has pins that are loc-tited into the center of the broken porcelain and only can be used once. The the electrode remover can be used.

In that location is some other method though, instead of gluing "one use" pins, a tool manufacturer has a dissimilar solution, The LIS65600 DLT broken spark plug remover mentioned before can be used as an alternative option to the 303-1398 & the 303-1203. The Lisle 65600 Ford spark plug remover, is designed to push the ceramic role of the plug further downwardly, just not into the cylinder. Then, the same tool kit removes the electrode shield. This automotive specialty tool kit is used in place of the two Rotunda tools (303-1203 and the 303-1398) at only a fraction of the toll. A special thank you to Bill at ProCare Automotive for being the first to endeavor this tool out and written report dorsum to usa, since then this is the tool we accept passed this data along. He said the LIS 65600 worked perfectly and was happy to know this tool can be used on more than one vehicle, dissimilar the 303-1398. Since that first sale of the LIS65600, we've sold hundreds with positive feedback! Nosotros've as well posted a blog that has pictures of the LIS 65600 DLT in use. Be sure to check it out and you lot'll have a ameliorate thought of how this tool works. Click the following to become directly to the Lisle 65600 DLT product list.