Aluminum Cylinder Heads

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Aluminum Cylinder Heads
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Spark Plug Blow Outs.

Ford has had a problem with the spark plug threads not holding spark plugs in their 4.6, 5.4 and 6.8 engines for awhile now. The aluminum heads have about five threads holding the spark plugs in place. If the threads fail the spark plug will eject, when it blows out it can break the ignition coil that is positioned over each plug. Ford does not recommend repairing the threads, they would rather the entire cylinder head be replaced with a head from Ford. Beware of purchasing a rebuilt head due to blowouts being so common, chances are the rebuilt head may have a repair insert that may not hold. Machine shops commonly use Heli-coils for repairing damaged or missing threads, however Heli-Coils are not the best repair in this instance.

The Heli-Coil is a thin coil that can fail due to the stress of cylinder compression and the fact that only a few threads are used to secure the spark plug. With this particular Ford spark plug problem, one of the best specialty tool inserts available is the CAL389-100 (much thicker than the Heli-Coil brand), it can be used in the vehicle saving down time and expense, the kit that it comes in has a short instructional DVD. Read on for Ford's latest spark plug problem.

Broken Spark Plugs.

Ford has redesigned the cylinder head on the 5.4 engines used in Ford trucks, Expeditions, Mustangs etc. unfortunately the new design has a different problem. When removing the spark plugs in these newer 5.4 Ford engines the spark plug can break leaving a metal sleeve (electrode shield) in the spark plug hole. The threaded part comes out but the remaining portion stays behind and can be a real nightmare to extract.

Ford has made a removal tool kit, the Rotunda 303-1203 for removing the spark plug sleeve when this break occurs. The Rotunda 303-1203 is a specialty tool that has been in huge demand from many unsuspecting repair shops that were performing regular maintenance on their customer's vehicles. The Ford TSB describes how to try to prevent the break, although the procedure yields less than desirable results.

The Ford Rotunda 303-1203 automotive specialty tool can be used to remove this poorly designed plug.

About the Author. Hi I'm Dennis Bandy, thanks for reading about my background. I've been an ASE Master Auto Technician for over 23 years and have also sold professional auto tools since 2005. I am in a unique position to help readers on certain automotive repair related topics since I've had personal hands on experience with many auto repairs and automotive specialty tools. Let me just say, this is not a hobby for me, this is my business. Your feedback is really appreciated, if you thought this article was helpful or informative, please rate it below (thank you in advance).

Half the battle when it comes to auto repair is having the right tools, that's why we have supplied name-brand automotive tools (like OTC, Makita, Ingersoll), shop supplies and automotive shop equipment at discount prices, at http://www.denlorstools.com since 2005, many readers put us on their favorites list and visit our site when auto specialty tool needs arise, we hope you do the same.

Mig Welding Aluminum: Tips for Aluminum Mig Welding

Want to find out the welding process for mig welding aluminum? In this article I'm going to tell you how to do it.

When you are welding ally with a mig welder there are a few steps that you need to take to make sure that your machine is set up to handle the job.

Type of aluminum welding wire to use

Nine times out of 10 you're going to want to use a 5356 grade aluminium mig wire. The 5356 ally wire is a little bit more firmer which makes it easier to feed through your mig welding gun.

5356 is normally used for general aluminum welding tasks such as toolboxes, truck tipper bodies and trailers.

If you need to repair cast aluminum such as cylinder heads or engine water pumps you would want to use 4043 grade.

Most welding shops will use 1.2mm diameter wire which is 0.045". The larger the diameter of the wire, the more firmer that it becomes. Because ally wire is very soft it is better to use the larger diameter wire for feed ability.

Stainless steel brush

You must use a dedicated stainless steel brush for cleaning the area where you want to weld. This is because there is an oxide layer that needs to be removed. Please make sure that you do not use this brush on anything else. It must only be used on the ally. If you use it for other jobs in the shed contaminants will get into the aluminium and contaminate the weld.

Welding torch liner type

It is required that you use a teflon or plastic liner instead of the standard steel coiled liner. This will make it easier for the wire to feed through the gun.

Feed rolls

To get more traction so that you have smooth feeding wire you will also need to get some u grooved feed rollers. Normal feed rolls are v grooved. The u shaped profile will allow for more surface area contact of the wire, thus giving it more grip to feed the wire through smoothly.

Larger contact tip

Because aluminum expands more than that of mild steel welding wire, you also need to use a slightly larger contact tip. The next size one up that is available will be ideal.

Only use the push welding technique

You need to angle your welding torch with the nozzle pointing towards the way you want to weld. By doing this the shielding gas will allow optimal coverage. If you use the pull mig welding technique you will end up having lots of black soot.

Finally you must use 100% argon gas

Argon welding gas is the proper gas to use for when you are mig welding aluminum.

About the Author

To find out more about mig welding aluminum follow this link to this website mig welding aluminum.

Repairing cracked aluminum heads?

If a aluminum cylinder head is cracked between the "intake" and "exhaust" valves, what is the best method of repairing it? Do you tig weld it or drill and plug the crack? Or, is there something else that I don't know of? Please explain which method is better and why? Thanks.

your better off taking it,,to a shop,,and maybe exchanging it for a good one they are really hard to weld up,,you can tig weld them,but the most of the time it wont hold,,id exchange it,,and get a good one,because this is going to be more of a headache than i think you realize to do,,i own a repair shop,,and have tried it before,,and i had no luck with making one last,,i finally just got a good one,,and put on it,,good luck with it,,i hope this help,s.

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