Re: Ford Pickup = \"Found On Road Dead\"
Jim,
I feel for your frustration, just keep in mind, none of the things you have mentioned have anything to do with Ford. You have an 11yr old truck that has presumably spent its complete lif in the rust belt.
First off, the Champion plugs are about as cheap as you can get. They only belong in lawn mowers, and another brand(that shall go unnamed). You also have to keep in mind the installation. Ford has had other issues more recently that was also mentioned in your post, regarding their modular engines.They have been know to blow the plugs out of the alluminum heads due to improper torque when they have been replaced. Be glad you didnt have this on a new one.Since you live in New England, I would highly recommend using an anti sieze on the threads and Motorcraft plugs. You should always use the factory ignition components.
I would be willing to bet, that if you researched the life of your new "truck" you would find that it has been used in more heavily salted areas than you think,maybe some snow plow work??
Since you have a Windsor style engine, you should be fine with the head job. I would recomend though that you go ahead and have the heads machined while you have them off. At 90k miles in those conditions, it would be well spent money to have the valves done and they could also handle the drilling and tapping for you.
I live in the south where we dont see that kind of stuff often but, when we do, their all like that regardless of brand. If you havent seen the vehicles in Detroit, you'd also be surprised. Even the "Almighty imports /forums/images/graemlins/cool.gif" are air conditioned by rust preforation. It's just a cancer that effects them all, some more than others due to the envirionment they are subject to. Luckily the newer vehicles use much better steel than was used in the past.
Good luck with your project.