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Old 07-14-2008, 05:36 AM   #1
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7 Hour spark plug change!!!! (56k no way)

No exaggeration. I started at 1 pm, and finished at 8 pm- but I did take a break to eat 2 pieces of pizza. I figured the first time would take a while, but I didn't think it would take that long. I could do my old 3.0 van in 2 hours.

Here's what it looks like together, this pic taken after I'd finished.



And the dash- ya gotta remove the engine cover.



Here's what you have to take off to start with- more has to be removed one time for certain plugs.





Sometimes you have to turn around in a position you wouldn't think of just to work it.


Hey honey I think your finger is in the pic!

Here's what that side looks like from under the hood. You can see the #1 plug, it was the only one you could reach from the front after removing the alternator. Those hoses there are actually molded into a T for the rear heater. Those were a big problem- something I didn't have on my old van. There was barely enough room to get a short socket on the bolts that held the alternator on, and I couldn't reach very far back from the front.




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Old 07-14-2008, 06:18 AM   #2
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I thought the passenger side was hard, but the driver's side proved to be worse. The wires were routed through the gap between the upper and lower intake manifold. I had to use a string tied to the old wire to pull the new wire in. To keep it from getting caught on the fuel injection harness, I ended up using half hitches on end of the boot so it pulled from there.



Here's the back side where the plug wires route through- the plastic on the left side is the coil pack, and the right side is the upper intake. As you can see the hoses for the heating and cooling in the rear were a pain to work around.



The first one (#4) was easy to remove, but for#5, I had to build this heavy duty swivel with a 1/2 universeal to get around the EGR I couldn't remove without jacking the van and disturbing the black widow that lives in the driver's side spring seat. I wish I'd taken pics, when I first got this van it was infested with at least 15 black widows- male and female. Anyway, that was for tightening the #5 plug, removal was easy since it was only finger tight!! I'm wondering if that was the ticking sound I'd been hearing after the van warmed up. I don't know why Ford's loosen up like that, but every cast iron head Ford I've had loosens spark plugs over time.



To get the last one, I had to fiddle my flexible end ratchet in there and reach way down, once again, would've been easier if I could get under this side of the van without endangering my life!
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Old 07-14-2008, 06:27 AM   #3
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This would only take a few more minutes if I could get my tongue back inside my mouth, I don't think I'm holding my mouth right or something.



WHAT?!?!?!?! Are you crazy, I'm not doing this again for at least another 100k miles!! What do you mean I need to use hand cleaner on my face?

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Old 07-14-2008, 07:47 AM   #4
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Good old Aerostars! Any thing beyond an oil change is a major job on one of thoes due to where the engine sits, etc. I remember watching my uncle and dad tear apart my uncles Aerostar when i was a wee one. Just about any repair required the tear down you did on yours! Ah Memories!

And I gripe when it takes me about 2 hours to do the Plugs on the Sideways V6 in my Taurus!
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Old 07-14-2008, 08:00 AM   #5
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Vans Suck.
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Old 07-14-2008, 09:31 AM   #6
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Good old Aerostars! Any thing beyond an oil change is a major job on one of thoes due to where the engine sits, etc. I remember watching my uncle and dad tear apart my uncles Aerostar when i was a wee one. Just about any repair required the tear down you did on yours! Ah Memories!

And I gripe when it takes me about 2 hours to do the Plugs on the Sideways V6 in my Taurus!
I remember my parents Aerostar as well. That engine was definitely cramped. I remember my dad saying he needed to change the plugs. He looked around under the engine compartment and said "I don't think so!"

He ended up taking it to the dealer. As stated earlier, vans suck to work on.
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Old 07-14-2008, 09:56 AM   #7
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Makes You Want To Go Work On The Foci For Fun Doesn't It!!!!! Lol
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Old 07-14-2008, 09:59 AM   #8
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Ah yes, the Aerostar......

Had a 1988 Eddie Bauer (short, with the 3.0) back around '93. Great little van. Started thinking about it, and I do not remember even attempting to change the plugs in that thing. I seem to recall something about techs at the Ford dealer DROPPING THE MOTOR (with the whole front subframe and suspension) to change the plugs......easier than what you did, with the correct tools and equipment.
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Old 07-14-2008, 10:04 AM   #9
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man, what a mess! you should get a trophy for that one
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Old 07-14-2008, 10:23 AM   #10
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hahahahahahaha..........that sucks!
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