Looking around at some trucks for work and have noticed that F-150 and F-250s with the 5.4L are typically cheaper than Chevs of the same years with the 5.3L. I have heard the horror stories of the spark plug issues with the 5.4L, but have not personally run into anyone that has had those issues. Are there any other real drawbacks to this engine? Any particular years to avoid or certain years to look at? And how serious or common is the spark plug issue?
The spark plug issue is common with trucks that have seen routine scheduled maintence.....the threads on back pass side(hardest to get to) can get worn/stripped out due to the odd location and difficulty in changing the plugs. A simple helicoil solves the problem when it manifests. Also note, this problem only effects 5.4L 2V mod motors(3v ones started in 2005 for the trucks)
Otherwise they are a bit thirsty(more so in the super duty series) and its always a good idea to have spare coil packs. They really are nice trucks though.
My biggest beef with the 5,4 besides working on them is the power delivery is "weak" compared to the LS's.
In reply to Ranger50:
They are almost too smooth in that regard....the 3v does have some punch to it though. 
Our Expedition tended to cook off one of the coil packs about every 60,000 miles
Our Expedition did a buttload of towing, hauled kids, materials and took us on several vacations.
I did the plugs at 200K they were old and crusty, all 8 came out fine, never did them again, the maintenance was very reasonable for a rusty old truck.
I recall doing an alternator, a coil pack, a plug wire and a battery
It got 17 mpg all day, and 14/5 towing.
Strong, reliable and comfortable.
What is wrong with that combination?
Early ones strip plugs, and are fixed "easily" with a Timesert kit. Late ones break plugs on removal, which are easily removed with a Lisle special tool. Coils are an issue, but are available and not tragically expensive.
Make sure the oil has been changed. They tend to have some cam phaser/chain issues if they have been ignored.
Gas, gas, gas. You're gonna need it.
The 5.4 3v is a pain in the ass when it comes to spark plugs. You're going to break the original plugs when you try to remove them. Be prepared. When reinstalling them, use anti-sieze. Plenty of it. Other than that, they are fuel hogs.
I have a 2004 5.4L 2v swapped into my 2000 P71. Much better than the 4.6L.
I had 2001 F159 4x4 Super crew with the 5.4. Great truck, but it couldn't pass a gas station without stopping. Seriously, it was the only vehicle I ever had that you could watch the gas needle move towards E while driving...
Cool, thanks guys. I heard of these issues on forums and such and they always seemed to be blown out of proportion. I've had to use a few work trucks that had the 5.4 2v in them and they never seemed to have issues, but they were always leases and never got enough wear on them to see these issues.
How do I feel about them? Well, the last two purchases for my fleet of contractor vehicles have been Chevys. What does that tell you?
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