Yup, that be cracked.

 

Replace it, it's junk.

 

Nope, it's good - cover that whole area where it's cracked with JB Weld and run it for another 50k. I've done the JB Weld repair to several coil packs with 100% success (so long as the coil pack isn't malfunctioning aside from the crack - arcing). I repaired the one on mine a little over a year ago. Zero issues. This repair stems from VW VR6 ownership. The factory coil packs on the VR6 are pretty much bolted to the head and they like to crack due to the extreme heat cycling. Same with the Focus.

OmniFocus & I were just talking about this regarding the LeMons race car - they chewed through 3 aftermarket coil packs on the Caravan during one race. They replaced the failing ones with their "damaged" MOPAR pack and it ran the entire second half of the race without issue. Some people use high-heat silicone to patch it up, but I find the JB Weld holds up better.

 

I ordered a new one. It also has a crack in the bottom epoxy...

 

So long as you ordered a Motorcraft - I've yet to find an aftermarket coil pack that's worth a damn for any car. Hence the JB Weld repair. I can see ordering a new one if you have multiple cracks. Just for gits & shiggles, if you have some JB Weld handy - try the repair and see if it works. I just use some 80 grit sandpaper on the whole surface that needs to be patched up to ensure good adhesion, and put a nice, thick layer of JB on there. It's worked like a charm for me every time.

 

Yes, I ordered a Motorcraft Coil and plug wires. I'll try the JB weld tonite after the motor cools off.

Just went out to the shop and pulled the coil to epoxy the crack and got to looking harder at it. It's got cracks on all the plug towers as well as all over the outside. I got a small round file and hit all the cracks I could see. JB welded them and gonna drive it later. I'll keep you posted.

 

Cool, I'm curious to see if it works out. I just snapped a photo of mine, and you can see I need to pull the thing out and re-do it, but this is after a year that includes a track day, a couple auto-x days and a 45-mile per day commute. I don't have any issues with it currently, though:

What I really need to do is make a quick & dirty heat shield. This side of the coil pack is right up against the head, and there's plenty of room for a heat shield.

 

OK, Still sputtering and wont rev past 5k.Please lord, let the new coil and wires save me.....:bang:

 

That's the symptoms a friend had. We replaced just his coil and it fixed the problem.

 

Once you get a crack and the internal coils get introduced to atmosphere you have a very high chance of corrosion which will lead to cross spark.

I personally NEVER waste my time with a cracked coil pack. It gets replaced by an OEM unit unless it's just a pinch replacement until an OEM unit can be had.

 

Re: ignition coil...cracked? UPDATE!!!!!!

I got a Motorcraft coil and wireset from rockauto and all my stumbling, bucking, and no power issues have been cured. Hallelujah! Ran her up to 6500 rpm in every gear, smooth as silk. Car has run rough since the day i got it, didn't know how nice she would be running like she should.

Thanks guys...

 

Man 6500 RPM in 6th must of been like .. 145mph+ ... you should slow down. (sarcasm)

Glad to know it's all fixed!