Annoyed

[demarpaint]

The title sums it up. I have some down time from work and decided to tune up the 93 Aerostar, Plugs, cap, rotor, gas and air filter. I estimate over 80,000 miles since the plugs were last changed [I'll have to check the log]. The wires were coated good with Dielectric grease so they popped right off the plugs, at least something went OK.


First mistake was I started late in the day. The two prior tune-ups were professionally done, this I wanted to do myself, and be sure all 6 plugs got changed.

Started on the passenger side, removed the tire, and got the front 2 plugs out, the rear plug closest to the firewall is a horror story. I busted the porcelain, and noticed that the plug was a Motorcraft plug the other 2 were Autolite Platinum plugs. The mechanic didn't change that plug, funny thing was I had a feeling that was going to happen, but the last time it was tuned up I didn't have the time, and the first tune up was done by the prior owner.

This porcelain broke, and this plug isn't budging even with a 2' breaker bar on it. I'm afraid to really bear down on it, so I soaked it with PB blaster and decided to leave it alone till later or possibly tomorrow. Any tips from guys that did plugs on an Aerostar, passenger rear plug closets to the firewall. I have a swivel on the socket, and about 2 1/2" of extensions on the wrench to get at it. The angle stinks, from the wheel well, and up top and under there is no room to move the wrench.


Thanks

 

[Chris142]

Back when i worked at pep boys and before thay paid commission
(hourly only)I did plugs and wires on a van like yours. Took me 7 hrs! Ya I still remember cussing the rear plugs.

 

[saberz]

My Xterra's #6 plug is kinda like that where its tucked mid-center half way down the back of the engine on an angle. Firewall is in the way making almost impossible to remove.

_____
|---

The | is where the #6 is located on my truck. Took me 4 hours, was easy getting it out, but hard as [censored] putting it back in at those insane angles.

Needed 2 3inch extensions, a swivel extension and a 8inch extension + a mirror. I had bruises on my hands and body from leaning on the engine because there is no other way about it.I feel your pain, especially now that I have to do it again because the plug was gapped wrong(wrong info).


My suggestion is, since it involves the wheel well, it to put it aside for a day that you can fully devote to it. You want to make it as easy as possible so if its possible to remove the fender/quarter panel i'd start with that to give you the most open area to work with. A mirror helps if you don't have full visibility of the plug.

Any ford forums give you tips on the plug change? I don't know how different a 93 is from a 95 but on a 95 you can:

Raise the car on ramps to change the # 3 plug, the one that is closest to the drivers side then reach around from above and get the #1 and # 2 plugs.
Pull loose the plugs off the coils for more room to reach behind the engine.

 

[EricF]

Do what the Ford Dealer spec's.. they drill a hole in the floorboard under the carpet, allows easy access to the plug. then they put a flat plug over the hole and you're done.
Then they charge you the 3hrs for it anyway, while it takes them literally 10minutes.

Makes sense that plug wasn't changed, I would put double platinum plugs in this time so you can go another 75k and not worry about it. Or invest in NGK or Denso iridium and go 100k!

 

[Herz]

my middle driver side plug in my sierra is a nightmare too. got like 3 inches to move the wrench gotta use 2 small extentions argh!

 

[SuperDave456]

My wife drives an Xterra, I haven't done a tuneup yet, but from what I hear the trick is to use 2 universal joints and 2 6" extensions to get around everything and if that isnt long enough add another extension.

I had a stuck plug on my '02 Ford Taurus that I tuned up 2 weeks ago. It had been in the ballpark of 90,000 miles since my last tuneup.
I didn't break off the porcelain but I thought I was heading in that direction. I hit it with a some compressed air, try to get any loose dirt out of there, then hit it with some Kroil. After about 10 minutes I hit it again with the compressed air again. Got the kroil everywhere but it might have pushed it into the plug deeper also.
After that the plug came out without an issue.

I replaced them with NGK platinum's, I should be able to go another 80-90,000 without an issue.

I thought Iridium's were good for over 100,000.

 

[Kruse]

I've owned four Aerostars over the years, I know they can be a real PITA. The heads are cast iron, so my advice is to keep soaking it and just put more pressure on it. I've always taken the dog house off just to get more light on the subject.
I've never drilled out any floors/panels to get access. As far as the 3.0 verses the 4.0, neither one has good plug access.

 

[oldmaninsc]

Originally Posted By: Kruse
I've owned four Aerostars over the years, I know they can be a real PITA. The heads are cast iron, so my advice is to keep soaking it and just put more pressure on it. I've always taken the dog house off just to get more light on the subject.
I've never drilled out any floors/panels to get access. As far as the 3.0 verses the 4.0, neither one has good plug access.


Yeah I agree. I've done plugs on both engines. I thought the 3.0 was slightly easier. On my 4.0 I had trouble getting my fat hand in there to get the spark plug wire off. I was fortunate the plug came out fairly easy.

I sympathize with you, and frankly I think "annoyed" is fairly tame to what I'd would call it. Every time I've done plugs on one of these vehicles, but arms look like I had a fight with a hungry lion!

Sorry, but I can't think of anything to tell you other than what's been said. I even tried taking the engine cover and going in through there but that didn't work at all! I usually jack the vehicle up and take the passenger side wheel off.

 

[demarpaint]

Thanks for the replies. First thing I did was remove the dog house. I have just about every kind of extension, angle, swivel, mirror, light, you name it. I think what is happening now is a chunk of the porcelain is wedged in the area where you get a socket on the plug. I tried blowing it out with compressed air.

I was thinking about drilling a hole, and might just do that tomorrow as a last resort. I think that would give me clear access. Funny thing is I was thinking about doing it, and now that I see it mentioned here it is sounding better.


Not sure if I should ask you guys that have worked on the these Aerostars but here goes. Which side is worse, drivers or passengers side for changing plugs? I could see this taking a good 5 hours or better.

Thanks!

 

[Kruse]

Originally Posted By: demarpaint

Not sure if I should ask you guys that have worked on the these Aerostars but here goes. Which side is worse, drivers or passengers side for changing plugs? I could see this taking a good 5 hours or better.



To me, the rear plugs on each side are bad, especially the 3.0 passenger rear.
I always jack it up and take both wheels off. After you've done a couple, you can easily chop time off that 5.0 hour figure.

 

[Kruse]

Originally Posted By: SuperDave456

I had a stuck plug on my '02 Ford Taurus that I tuned up 2 weeks ago. It had been in the ballpark of 90,000 miles since my last tuneup.


This is one reason I don't go 100K on plugs, despite what the manufacturers claim. The plug can function okay, but they sometimes seize in the head.

 

[demarpaint]

Thanks Kruse,

I have a bad feeling that the plug might be screwed up now. I wanted to cut a hole in the firewall near the dog house and go straight in. I have a 3" hole saw I'm going to "go for it" in the morning. I'll cut the hole then use the metal [I hope] for a plug, that I can silicone back in place.

If I messed up the plug I guess I can hope that an easy-out works. Who ever thought up the design of that engine bay must have gone to work for GM after Ford booted him. J/K

 

[oldmaninsc]

Originally Posted By: demarpaint

Not sure if I should ask you guys that have worked on the these Aerostars but here goes. Which side is worse, drivers or passengers side for changing plugs? I could see this taking a good 5 hours or better.

Thanks!



I'd say the passenger side - at least for me. I usually do the driver's side first, doesn't take that long. I usually spend more time on the passenger's side rear plug as I do the other 5!
Oh I forgot - I usually use a ratchet with the pivoting head. That seems to work the best for me.

 

[Turk]

Two things:

Get a vacuum to suck the piece out!

If the plug does not budge, tighten it, yes, tighten it, THEN loosen it. It's helped me get a couple out over the years...

 

[demarpaint]

I have to get a good angle on it. I have a 3 1/4" hole saw, I am going to cut an access port tomorrow, then hope that I can get a socket on the plug, without all the angles and long extensions. That's about the only good thing about beaters, if you have to do some off the wall alteration it's not so bad.

 

[ms21043]

It's been many years since I've worked on an Aerostar, last one I did was an engine change. If I remember correctly the way to change plugs on these is from directly underneath. You need to jack the van up and support it securely and work from below reaching up. I can't tell you exactly how to position yourself, I don't remember. What I do remember is once you figure out how to do it from below, you'll wonder why in the world people fuss with all these double universals/ drilling holes in the firewall etc.

 

[Gary Allan]

Quote:
but arms look like I had a fight with a hungry lion!


Yeah. I always envied those who had skinny forearms. Maybe long sleeves would help.

 

[demarpaint]

Originally Posted By: ms21043
It's been many years since I've worked on an Aerostar, last one I did was an engine change. If I remember correctly the way to change plugs on these is from directly underneath. You need to jack the van up and support it securely and work from below reaching up. I can't tell you exactly how to position yourself, I don't remember. What I do remember is once you figure out how to do it from below, you'll wonder why in the world people fuss with all these double universals/ drilling holes in the firewall etc.


I know you're right. My problem now is I have to be able to see straight in because I think a bit of the porcelain is messing me up, and the mirror trick isn't cutting it. I have the van in the air, on stands, secure with wheels off. I guess I'm not seeing it but this plug doesn't want to give up. LOL, it's almost as if it has a mind of its own, and is as determined to stay in as I am to get it out. I'm going to get an early start on it this morning, get the truck a little higher up and look again from under it before I start drilling. The drilling is a last resort, but I won't hesitate for one second to drill it.

Thanks

As far as hands and arms go, mine look like I came in second place fighting a Pit Bull.

 

[Kruse]

Originally Posted By: demarpaint
Who ever thought up the design of that engine bay must have gone to work for GM after Ford booted him. J/K


When the Aerostar was on the engineering drawing board, it was scheduled to have the 2.3 four cylinder engine and nothing else. When they realized that the V6 engines would fit, the workability went downhill from there.
If it makes you feel better, I know of a seasoned Ford tech who had the job of replacing plugs and wires on an Aerostar. After eight hours of trying, he walked off his job and did not come back. His job had to be finished by the other techs.

 

[demarpaint]

I can see why. I got that PIA plug out, small access hole and a smashed thumb. Now the drivers side I can't wait!

Thanks for the help!

Frank D