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  • Calvan 38900 thread repair kit, includes case not pictured.
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Calvan 38900-8 Ford 4.6, 5.4 & 6.8 Spark Plug Port Thread Repair Kit

SKU:
38900-8
Weight:
4.00 LBS
Shipping:
Calculated at checkout
Price:
$249.99


Product Description

Free tips upon request only when purchasing from us. Free 2-3 day shipping.This Calvan 38900 kit has 8 solid bushing type inserts. The insert's lip design prevents them from going too far and falling into the cylinder. The 38900 spark plug thread repair kit works on many Ford 4.6, 5.4 and 6.8 SOHC Two Valve engines. See below for more details on the application. Or as long as you're making a purchase with us call 800-734-8665 x251 for assistance in choosing the right kit, whether it's a Calvan or Time Sert. Replacement 389-100 inserts are also for sale individually if needed later. This kit uses inserts that are large enough in most cases to do 2nd time repairs when a parts store insert like Heli Coil Save-a-Thread or Dorman (made in China) repair has failed. The 38900 kit is also recommended for 1st time repairs. The inserts have a lip on the top that allows the inserts to be tightened down similar to how a bolt is secured.

Important - Please Read

Thread lock of some type is needed. We prefer High Temp Oil Resistant Seal-Tite & Clip (also equivalent to 277). However, some customers choose High Temp JB Weld 8297. The manufacturer says only one is needed to be used on the exterior threads of the insert when installing to prevent it from backing out on the next plug change. Some prefer to use the thread sealer on the threads and use JB Weld under the hat. Also recommended is an e-clip used to eliminate the possibility of the thread tap from falling into the cylinder if you tap too far! We've had customers use a paper clip or rubber band in the upper V-Groove of the tap, however the 38900-Clip is the retaining clip that we recommend since it's the most reliable. 

*Bonus-During checkout just write " Tips" in the comment section or mention that you want "tips"  when ordering on the phone and we'll email our exclusive tips. We've compiled these tips starting back in 2005. *We don't sell on eBay or Amazon - therefore, the FREE TIPS offer is only good when a purchase is made at DenLorsTools.com or WiseAutoTools.com.

This Calvan 38900 Kit Includes:

  • Line up Guide
  • Cylinder Leak Tester
  • Reamer (similar to a drill bit)
  • Tap
  • DVD and written instructions
  • 389-100 Inserts Quantity - 8
  • Storage Case
  • Emailed tips upon request when purchasing from us.

Make

Model

Engine 4.6

Year  *Exercise Caution

Ford

Crown Victoria

4.6 SOHC 2V

1992 - 2011

Mercury

Grand Marquis

4.6 SOHC 2V

1992 - 2011

Ford

Mustang

4.6 SOHC 2V

1996 - 2004 Excludes Cobra

Ford

Thunderbird

4.6 SOHC 2V

1994 - 1997

Ford

E150

4.6 SOHC 2V

1997 - 2014

Ford

E250

4.6 SOHC 2V

1998 - 2014

Ford

Expedition

4.6 SOHC 2V

1997 - 2004

Ford

Explorer

4.6 SOHC 2V

2002 - 2005

Ford

F150

4.6 SOHC 2V

1997 - 2008

Ford

F150

4.6 VIN W Only

2009  *38900 for 2V's only 

Ford

F150

4.6 3 Valve

2009 *See 39300 Kit

Ford

F250

4.6 SOHC 2V

1997 - 1999

Lincoln

Town Car

4.6 SOHC 2V

1991 - 2011

Mercury

Cougar XR7

4.6 SOHC 2V

1994 - 1997

Mercury

Mountaineer

4.6 SOHC 2V

2002 - 2005

       

Make

Model

Engine 5.4

Year *Exercise Caution                         

Ford

E150/E-Series

5.4 SOHC 2V

1996 - 2016

Ford

F150

5.4 SOHC 2V

1997 - 2003

Ford

F150

5.4 SOHC 2V

2004  *38900 for 2V's only 

Ford

F150

5.4 SOHC 3V

2004 * Some have 3V See 39300

Ford

F250 & F350

5.4 SOHC 2V

1997 - 2004

Ford

Expedition

5.4 SOHC 2V

1996 - 2004

Ford

Excursion

5.4 SOHC 2V

2000 - 2005

Lincoln

Navigator

5.4 SOHC 2V

1998-1999 *38900 2V's only

Lincoln

Navigator

5.4 DOHC 4V

1998-1999 *Some have 4V See 5553

       

Make  

Model    

Engine 6.8 

 Year                          

Ford

Excursion

6.8 SOHC 2V

2000 - 2005

Ford

F250-550, F53

6.8 SOHC 2V

1997 - 2004

Ford

Motorhome

6.8 SOHC 2V

1997-2004

Ford

E350- E450

6.8 SOHC 2V

2014-2016

Calvan Tools 38900, Ford spark plug insert installer is designed to aid in repairing Ford modular cylinder heads on 4.6, 5.4 and 6.8 2-Valve engines (NOT for 3V engines or DOHC).  *38900 is not recommended for holes larger than .678" (17.20mm). This is the O.D. (Outside Diameter) of the reamer in the kit which is 11/16". If the hole is larger than .678" see the  Time Sert 5600 kit which has a larger O.D. reamer which is approximately .73" (18.54mm). See our article for more information on this and other spark plug thread repair kits to fix Ford Spark Plug Blow Outs. Call if there are questions.

• Quality, fool-proof repair system that is fast, cost effective and simple to use.

• Used to repair damaged heads from blown spark plugs, with an alloy steel insert, which has no problems with heat transfer or grounding.

• M14x1.25 Taper Seat 389-100 thread inserts.

• The Calvan alloy steel insert is thicker than most competitive brands which allows for a superior repair even when a Helicoil Save-a-Thread was used previously and failed.

*It's recommended to use a video inspection camera to verify all metal shavings are out of the cylinder before installing the spark plug.

Use the 38900 kit right over the fender without removing the cylinder head. Alternatively, the kit can be used heads that are removed. Many customers decide to do all 8 so there's no future issues. 

Question - Which is better the Time Sert 5553 or the Calvan 38900? See our FAQ's video below for the answer to this and other questions. 

Over the Fender Repair for 2V 4.6, 5.4 & 6.8 liter engines (excludes InTech, see Time-Sert 5553)

Also works on 2001 and up SOHC engines with the Extra Step Material above the spark plug hole. The Calvan 38900 does not have a counter-bore like the Time Sert 5553 and 5600 to remove the step material before tapping the hole to accept the insert. The Time Sert 55518 counterbore is not designed to be used with the Calvan 38900. That's why TIME-SERT recommends for 2001 and up Romeo heads the 5553 or 5600 to be used since they include a 55518 counterbore. Using the 38900 on 01 and up Romeo heads can result in the spark plug being positioned up a little higher. However, we've had no problems reported when using the 38900 on 01 and up Romeo style heads. More information on how to identify these 2001 and up Romeo heads can be found in the following article -  Extra Step Material

Calvan 38900 Spark Plug Thread Repair Video

Calvan's larger outside diameter insert, which is considered a permanent repair is used in cases when smaller parts store temporary repairs have failed. The inferior parts store inserts are supposed to be held in by using a swedge tool on the top of the insert and hitting it with a hammer!

• Reduce vehicle down time and added expense by eliminating the need to disassemble the top of the engine to send heads to the machine shop.

• With the use of an inspection camera, a quick look into the cylinder after a repair insures there's no metal shavings remaining, prior to installing the spark plug.

• This kit comes with a "how to" DVD video (same as YouTube video above). This along with our info, the job can be done quickly and accurately.

* When written instructions are followed also covered in the included "how to" video, there's no faster or better repair available. The cylinder leak tester saves time when making sure the valves are closed. The line-up guide allows for straight reaming even on back cylinders. Use of an air ratchet with a socket on the reamer allows for a 90 degree (right angle) for easier drilling. This makes working in tight spaces more comfortable. The Calvan thread repair inserts have stronger threads than the originals. The cost of the repair is only a fraction of replacement cylinder heads, the head gasket set, coolant, labor, etc. Also, be aware that many re-manufactured cylinder heads have inferior repair inserts like Helicoils or Lisle. If you buy one of those patched heads you could still end up having issues. 

Bookmark or save this page to favorites, it has all the information needed to fix the common Ford spark plug blowout problem, including the instruction video, links to replacement inserts and the FAQ's article.

Using the Calvan 38900 Specialty Tool Kit

It's worth saying again "the Calvan kit has a much thicker insert that can be used when other thinner repairs like the Heli-coil Save-Thread or Lisle have failed to hold". Using the kit requires about the same amount of room as changing the spark plugs. Just a few steps more. The instruction video provides details on using the kit but there are more tips that we have written over the years since we've been selling this kit. These tips are emailed exclusively to our customers upon purchase, just ask us. We'll also personally answer our customer's questions if needed by email or phone, but we've found our written tips, help to clarify the job immensely for those doing this job for the first time.

At checkout just write "Tips" in the Comments section and we will email our exclusive tips for free when processing the order.

Tips - Emailed free after purchase.
Not researched enough? We understand the concern when faced with drilling into your engine. Rest assured this is a proven repair that has been done by many do-it yourselfers and professional techs alike. For even more information see the following page - Calvan 38900 Application and FAQ's or give us a call at 800-524-9783 x251.

Note: We are not responsible for typographical, pictorial or pricing errors. It's our goal to offer the most complete and accurate automotive tool source possible for our customers. We strive to correct errors in listings and provide improved pictures and item descriptions whenever possible. If you question the accuracy of any of our listings please notify us of your concern prior to purchasing.

Write your own product review

Product Reviews

Showing reviews 1-10 of 18 | Next

  1. Easier than it seems 5 Star Review

    Posted by on 7th Dec 2019

    I have a 2001 F250 with the 6.8L V-10. The 2V heads have blown 4 spark plugs, 3 of which were repaired before I took possession of the vehicle. The previous repairs were done with thread savers. I did a lot of research and watched numerous, detailed video’s on performing the repair with the CalVan inserts. I didn’t want to pull the heads and the CalVan kit seemed to be one of the best solutions for an over the fender repair. I am not usually one to hesitate when it comes to vehicle repairs, but I was a little intimidated by the idea of reaming and tapping the heads while still on the truck. Followed the directions and tips provided in the videos, to the letter. Everything went like clockwork. Thread savers came out with an “easy out” and installing the new inserts wasn’t nearly as difficult as I had imagined. I am confident in the product and the installation procedure. The fact that this is a permanent repair provides a lot of “piece of mind” at a very reasonable price. I would definitely recommend this kit and would probably perform this repair as a preventative measure on any Ford Triton engine that I end up with in the future.


  2. The ONLY real solution for a blown spark plug in a Ford Triton engine! 5 Star Review

    Posted by on 5th Sep 2019

    After much research this CAL-VAN 38900 repair kit was the Only real choice for a permanent high quality repair. I followed the associated You Tube Videos ( Especially the ones by Ron Williams ) very very carefully and ended up with a completely successful solution to what could have become a very serious problem.


  3. Simple use 5 Star Review

    Posted by on 29th Jun 2018

    Had one hole done three times by someone else because I was to cheap to by the tool. I finally bought it after everyone told me I had to replace the head. The inserts are very well built the tool is super simple to use and they answered all my questions. Now I have the price of two kits in the repair. Buy this first and save yourself the money.


  4. Great tool! 5 Star Review

    Posted by on 15th Apr 2018

    2003 town car with about 192k! The 4th cylinder spark plug blew out. I didn’t even think it was possible. It destroyed the plug and ignition coil. I was able to repair the head with only removing 1 vac line and coil connector. No issues for over a week.


  5. Don't listen to Ford. 5 Star Review

    Posted by on 12th Apr 2018

    My Ford dealer told me the best fix was to change the head because standard Heli-coil fixes didn't last long. It would have cost $2000 or more and the problem would have undoubtedly returned. A friend told me about Calvan and decided to invest in the 38900. Best tool I ever bought. It took me about 20 minutes to repair a 2010 Crown Vic with 99574 miles on it. That was because I had to answer the phone three times before I was done.


  6. Cal Van best one going!! 5 Star Review

    Posted by on 7th Apr 2018

    Bought this tool on the recommendation of Ron Williams U tuber, and from Wise tools very helpful Thanks Dennis! Works great easy to use permanent repair. Just finished my 1st on a 2004 Lincoln Town Car 4.6 went smoothly. Next is a 1999 Ford F250 5.4.

    From Wise: Thanks John. Glad it worked well for you.


  7. "Great product, great customer service" I am very pleased! 5 Star Review

    Posted by on 15th Dec 2017

    I have a 2010 Crown Vic, Police Interceptor 4.6 V-8. At 20 miles per hour in town, My # 3 spark plug and coil, went south on me, 2 blocks from my home. I through the 4 way flashers on and brought her home. Called my Mechanic and had AAA flat bed it to the garage. I called Wise and they recommended the best set of tools and the best price. Very much informative and walked me through the ordering process. It arrived in 2 days, with free shipping. My mechanic was very impressed with the quality and all the instructions and informative video that reassured his capabilities to repair my engine. I picked up my car that day, went for the recommended oil change, and took her out for a test run at a conservative level; she runs great... Bottom line, I highly recommend Wise products and all they have to offer to their customers.

    From Wise: Wow thanks Larry, glad everything turned out well.


  8. Best tool for this job! 5 Star Review

    Posted by on 14th Dec 2017

    Bought this kit for my 2001 Ford F150 Supercrew 4x4 with the 5.4 triton. This kit made the job of repairing a blown out spark plug easy! Right tool for the Job!


  9. If I could give this product a 10 I would. 5 Star Review

    Posted by on 10th Nov 2017

    My son and I bought a project 99 f350 with a V10 that was spitting out the plugs and inserts that the previous owner had installed. When the previous owner did the repair he used the cheap inserts and they blew out with the sparkplugs. I saw one of Dennis’ videos on YouTube and thought I would give this kit a try before I pulled the heads and boy am I happy I did. This kit worked awesome and I could not be more happy with the results. This kit is so well thought out that it is easy to do the repair. Between the guide, clip and thread lock it’s a no brainer to take care of it. The only thing I will say is make sure you have a good bore scope so you can clean out the cylinder by blowing it out and keep checking it to make sure it’s clean. That seriously was the hardest part of the job. Drilling it and using the kit was so easy it only took 10 minuets to drill, tap and install the insert. Great kit...

    From Dennis: Thanks Mike!


  10. Thanks! 5 Star Review

    Posted by on 7th Nov 2017

    It worked great and now my 2000 5.4 Expedition is back on the road and running good again. I would recommend your kits to anybody that needs the same blow out spark plug repair.


Showing reviews 1-10 of 18 | Next

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