If there’s one part you don’t want to have trouble with in your vehicle, it’s your engine. And when it comes to powerful engines, Ford’s 4.6L V8 is a popular one found in many of its pickup trucks, as well as some of its SUVs and sedans.
But have there been any 4.6 Ford engine problems reported with this motor?
Unfortunately, yes, and many of these issues have never been formally recalled.
Some of the more common problems reported with this engine include:
- Engine fires
- Spark plug ejection
- Fuel pump issues
Before you buy a used Ford, whether it’s an F-150 or another model with this 4.6L engine, take some time to familiarize yourself with these common complaints. We’ve outlined each complaint for you below, along with details of specific incidents and repair costs.
More about Ford’s 4.6L Engine
Ford’s 4.6L V8 engine made its debut with the Lincoln Town Car in 1991. As the engine saw success in the Town Car, however, Ford began to add the 4.6L engine as an option on many of its cars, trucks, and SUVs.
The 4.6L motor was most commonly seen in the Ford F-150 through the 2011 model year, though it could also be found on other models including the Mustang and Expedition.
Throughout the years, this engine evolved from a two-valve V8 into a four-valve design before it was eventually replaced by Ford’s 5.0L “Coyote” engine.
Common 4.6 Ford Engine Problems
2002 Ford F-150: Reported Engine Fires
NHTSA Complaint IDs: 11171391, 11194582
While Ford’s 4.6L V8 engine saw a lot of success and popularity, it was not without its flaws. Multiple recalls were issued on the engine in its earlier years, and many complaints have been filed regarding this engine that have not been formally recalled.
One unfortunately common complaint has been that the engine is known to catch on fire; this is often reported on earlier models, including the 2002 F-150.
In one NHTSA report from 2019, the owner of a 2002 F-150 reports that the engine caught fire shortly after the vehicle was parked and turned off. Ultimately, the entire truck was engulfed and became a complete loss.
A similar report, also from 2019, describes an “explosion” from underneath the hood of a 2002 Ford F-150 that led to an engine fire, thus totaling the vehicle. In neither instance was the vehicle inspected by a mechanic to determine the cause.
2003 Ford F-150: Spark Plug Ejection
NHTSA Complaint IDs: 10934056, 10927079, 10910692
Spark plug problems have also been frequently reported with Ford’s 4.6L engine, including complaints of spark plugs literally being ejected from the engine on the 2003 Ford F-150.
In one December of 2016 NHTSA complaint, the owner of a 2003 F-150 reported that a spark plug ejected from the engine, and went on to mention that this appears to be a common issue with this particular engine.
This is just one of multiple NHTSA reports of spark plug ejection on this particular model.
Several Vehicle History reviews also mention this issue, including one from Curtis A. in August of 2020. He claims that the vehicle blew a spark plug, although it was a relatively easy fix. Another reviewer, Lori B., claims that this has happened to her twice.
2004 Ford Mustang: Spark Plug Ejection
NHTSA Complaint IDs: 10722477, 11006037
The 2003 F-150 appears not to be the only model affected by this spark plug issue, as there have been multiple complaints about the spark plugs ejecting on the 2004 Ford Mustang as well.
One owner filed an NHTSA complaint in May of 2015, reporting that after starting the engine, a spark plug ejected from the engine block and exploded. After bringing the car to a mechanic, the owner claims that the repair cost $2,400.
In another NHTSA report from 2017, the owner of a 2004 Mustang explains that the spark plugs “have a tendency to blow out,” causing damage to the vehicle. Meanwhile, this can create a fire hazard as fuel vapor may be released into the engine compartment when this failure occurs.
2006 Ford F-150: Fuel Pump Causing Engine Stall
NHTSA Complaint ID: 10948553, 10617765, 10610231
Yet another relatively common complaint made about Ford’s 4.6L engine is related to the 2006 Ford F-150 and its fuel tank failing, which can supposedly cause the engine to stall out.
Numerous NHTSA complaints describe corrosion of the fuel tank causing an engine stall while the vehicle is in motion.
In one particular NHTSA complaint, the owner of a 2006 Ford F-150 describes how the vehicle’s engine stalled while traveling at speeds of 55 miles per hour. Upon having the car towed to a dealer, the problem was found to be fuel pump damage to the tune of nearly $500.
