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

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 1-4 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
• Calvan 38900 Instructions

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.