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Calvan 38900-8 Ford 4.6, 5.4 & 6.8 Spark Plug Port Thread Repair Kit

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SKU:
38900-8
UPC:
047084389003
MPN:
38900
Weight:
4.00 LBS
Shipping:
Calculated at Checkout
On Sale
Now: $239.99
Was: $259.99
Frequently bought together:

Description

We quality check all inserts and tooling for manufacturer defects prior to shipping and provide free tech support for our customers at 800-734-8665 x-251. Free tips sent only when purchasing from us at the normal sales price. We will match competitor's pricing (no tips or tech support) give us a call at 800-734-8665. Most customers that viewed this listing, purchased the combo kit that also includes JB Weld and Thread Locker, 38900-Combo.

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. The High Temp Oil Resistant, permanent type Seal Tite (also equivalent to 277) is used on the exterior of the insert threads. As an additional measure High Temp JB Weld 8297 can be used just under the lip for sealing and filling any voids in material. 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. In our opinion a little extra insurance is not a bad thing. Also included, is an e-clip used to eliminate the possibility of the thread tap from falling into the cylinder if you tap too far! The retaining clip is now included for the thread tap. The roll pin in the drill bit/reamer is the only "stop" needed for it. Since the inserts have a lip they cannot be screwed too far like many parts store inserts. FYI - Parts store inserts can drop into the cylinder if screwed in too far!

 

*Bonus- As mentioned above, we send our exclusive tips and answer questions for our customers. We've compiled these tips since 2005. *We don't sell on eBay or Amazon - therefore, the FREE TIPS offer and tech support 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
  • Video on our product listing
  • 389-100 Black Oxide Inserts Quantity - 8
  • Storage Case
  • Tips sheet sent with kit 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, commonly used for first time repairs and for second time repairs when a parts store insert measuring .66" OD (Outside Diameter) fails. The 38900 kit is used to repair Ford modular cylinder heads on 4.6, 5.4 and 6.8 2-Valve SOHC 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. A little more room needed than is required for changing the spark plugs.

 

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

 

• M14x1.25 Taper Seat 389-100 thread inserts. New design is black oxide treated to help prevent corrosion.

 

• 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 making the hole bigger.

 

*It's recommended to use a video inspection camera to verify all metal shavings are out of the cylinder before installing the spark plug. Some customers take other measures, mentioned in our tips.

 

Use the 38900 kit right over the fender without removing the cylinder head. Alternatively, the kit can be used on 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.

 

• The manufacturer's instruction video, along with our tips and tech support, ensures 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. Otherwise we will send a printed copy of our tips with the kit when purchased from us.

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.

 

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8 Reviews

  • 5
    Kit worked great and excellent customer support

    Called and spoke with Dennis, very helpful guy. Answered all the questions I had and shipped the kit out fast. The kit worked great and made a quick job of the plug reset. I’m a shade tree mechanic and have never reset a plug before and this was excellent and worth the money for a quality set of tools. If you have a blown out plug on a Crown Victoria, I recommend not buying anything but this.

  • 5
    Best kit ever purchased

    2005 ford f150 4.6 SOHC this kit is far greater to purchase than going the cheap method of tapping threads. The guide insert ensured that the drill tap and tap drill perpendicular into the spark plug hole. The tool is very easy to use, just follow the instructions to make sure the valves are in there seated position and piston down the cylinder bore.

  • 5
    Do it Right

    The is the best product to re-tap and add insert to the blown out spark plug port in a 2 valve ford 4.6 motor. Wise Auto provided a great customer service by performing a quality check and responding to my inquiry about expediting shipping. Highly recommended!

  • 5
    Definitely recommend

    I have tried other tool kits to fix the problem and nothing compares to how good this works.

  • 5
    Great product

    I installed the Calvan spark plug insert on a Ford 5.4 motor. It was not that difficult to install but I have been doing automotive repairs since I was a young man with my father and no further certified schooling. The instructions were very good and you-tube was another resource that I used to insure success. I would highly recommend this product and also encourage the purchase of the kit that has all 8 inserts to save time when another spark plug is possibly ejected to save time. From Wise: Glad to hear everything worked out well! Dennis

  • 5
    Works exactly as it should

    Simple tool to use, if you follow installation instructions it would be hard to mess up, allow ample time for thread lock/JB weld to cure and your good to go. Far superior to any helicoil products out there. Only inserts that last on the Triton motors

  • 5
    Works exactly as it should

    Simple tool to use, if you follow installation instructions it would be hard to mess up, allow ample time for thread lock/JB weld to cure and your good to go. Far superior to any helicoil products out there. Only inserts that last on the Triton motors

  • 5
    2003 5.4l #3 Blew again

    Ford 2003 Expedition 5.4l #3. 160k on engine, 50k on dealer installed insert. Heard that Cal-Van (Horizon) had a problem with QC, Checked all inserts with spark plug and 3/4-16 nut, PERFECT (of course because WISEAUTOTOOLS.COM had already checked it. THANKS !!. Once you get all the crap on the engine out of the way it is straight forward. All tools in the kit worked perfect. JB under the hat and couldn't find 266 so used permatex 27200, we will see. If I had it to do over would have just bought the full kit from Wise. If I can do it (with youtube) anyone can. Shipping was slow USPS FL to ID couple of weeks, not Wise Fault. The inserts now have Ferrous (magnetic)? From Wise: Thanks again. Yes USPS has been problematic lately. We always do our part and ship out right away. We have been using UPS when we can lately since USPS has been slow. We not only check the inserts we also check all tooling for quality control. Yes, the inserts are attracted to a magnet.

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