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My '93 w/3.0 has the TFI module located on the passenger side fender wall, just behind the airbox.It is attached to a large heatsink and looks exactly like what aerocoloado posted to you previously. Hope this helps
Thanks for the info. That's the 2nd time you've helped me. I'll share my troubleshooting woes. Love the van. I may have to sell due to a move overseas and I can only take 1 with me. The one with lower mileage of course. 97 Expdtn. Thanks and aloha
Reever,
Thanks for clarification. Mine is a 4.0 and the last 3.0 I looked at was years ago. With all the trouble Ford has been through with their TFI module, it is not surprising they moved it as far away from the engine heat as possible. (BTW, I'm still scratching my head over your post water pump ignition woes. Can't even begin to conjure up a reason for that. It's always something laughably simple in the end.)
Thanks again. That's someone else's Aerostar that leaked everywhere and shorted something out. I am still searching for the "Refuses to start when wet outside" situation. I thought maybe the Ignition control module was getting wet. I took it off the wall and heatsink cleaned it off, applied die-electric grease and remounted. I suspect water is leaking on the sparkplug closest to the powersteering pump. When it does rain I've noticed water collecting on power steering fill cap. Thanks for all of your help.
Rock,
If you look just above the power steering pump, there is a long, flat plastic piece hanging down from the vents under the wind shield. I believe this is the drain vent for the air vents. Mine also drops water down into the steering pump area. I believe that is the "way it is". You might be able to pull it forward slightly to keep it from draining onto the spark plug. Hope this helps.
Later,
Reever
Thanks,
I'll do that. Do you think having one spark plug soaked with water keeps engine from firing? If thats the case then I've solved my woes. I'm really digging. Rock
Rock,
If the sparkplug boot is on tight enough, it should be ok. I wouldn't think that one "wet" plug is all of your problem. The entire engine compartment gets wet when it rains, snows etc. All of the plugs/ sparkplug boots become wet at the same time. I know what you are talking about with the water from the drain tube going onto the power steering pump. Did you check the distributor cap? If it is old it can accumulate moisture. How about new sparkplug wires? Older wires can break down and cause rough starts. I'm just throwing stuff out here. How about the terminals on the battery? Clean and tight? I gotta get back to work.
Later,
Reever
came to this site for this exact problem. 93 aerostar will not start when it rains. local mechanic menioned the vent/flap thing made a fix...by installing a piece of plastic to reroute water....still wont start when wet...same guy says its a common problem on this vehicle. if its a common problem why is it so hard to find other reports and a fix? will check back later for any updates. thinking ill just buy a vehicle cover for now
My next step is to replace plug wires and plugs with original motorcraft equipment. I may even check and replace distributor cap. I'll let you know the results. Right now it's still wet here on the E. Coast. Have to wait for a warm/sunny day then I'll let the Ford dealer tackle the problem.
Well I opened up the engine panel cover and took off the distributor cap, wiped out and covered the contacts with die-electric grease. Greased the rotor contacts and plug wires on top of cap as well. It has rained once since then. So far no problem with it starting. It's supposed to rain for the next 2 days. Hope all goes well.
Evrything is still going strong. It rained all day and night the past few days. When out to start van and fired up right away. I pretty much replaced the ff. items thinking it was causing my hard starts: Idle control valve, O2 sensor, Coolant temp sensor, air charge temp sensor. It all cost about 90+ dollars. I have no regret since the van has 196,000 miles. I'll keep posting. The forum has really been helpful. RHayag
Did you ever figure out what this was? I just picked up a 92 from en elderly couple and they tell me the van has abeen towed three times because it wouldn't start in the rain or damp weather. Otherwise van is perfect. I can't find anything wrong with it.
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