deffective new Coil Pack
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Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
deffective new Coil Pack
while re-assembling the 1997 4.0 after doing the upper Intake "O" rings and the Revised Fuel Rail Intake Gasket, (misnamed as the "Upper Intake Gasket"), my nephew, a certified Honda mechanic with more honors that I have time to list, noticed the replacement Coil Pack Terminals or "Posts" were not straight up at 90 degrees as they should. This new Coil Pack is "Made in China". I installed it back in February and the reason for its replacement persisted, i.e., a missing at idling.
When we compared the old Motorcraft "Made in Spain" coil pack with the new one, by golly, it's no wonder why I couldn't get the spark plug wires to "lock" onto the End Terminals, the terminals are angled at such an angle that the locking tab cannot go down enough to lock in place.
and then he noticed the diameter of the Terminals is also 1/16th" smaller than the old coil pack.
When I purchased this new Coil Pack, even the VIN was supplied to the seller to make sure I was getting the right part.
I'm not going to mention the part seller because he refunded my money and told me to dispose of the part as it is obviously deffective.
Here's two pictures showing the problem:
When we compared the old Motorcraft "Made in Spain" coil pack with the new one, by golly, it's no wonder why I couldn't get the spark plug wires to "lock" onto the End Terminals, the terminals are angled at such an angle that the locking tab cannot go down enough to lock in place.
and then he noticed the diameter of the Terminals is also 1/16th" smaller than the old coil pack.
When I purchased this new Coil Pack, even the VIN was supplied to the seller to make sure I was getting the right part.
I'm not going to mention the part seller because he refunded my money and told me to dispose of the part as it is obviously deffective.
Here's two pictures showing the problem:
Thread Starter
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Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
waterbear:
I wonder how many Aerostar owners have had this trouble with those coils.
I replaced the original coil pack (bottom picture), and it is working fine. That's why I never throw away old parts.
I wonder how many Aerostar owners have had this trouble with those coils.
I replaced the original coil pack (bottom picture), and it is working fine. That's why I never throw away old parts.
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Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
93nighthawk, I replaced the coil pack because there was a constant missing that to me felt "electrical", and after getting codes from Autozone, I concluded it was the coil pack, which it wasn't, it was the Fuel Rail Gasket and Upper Intake "O" rings which my nephew correctly diagnosed.
after doing the latter repair, the engine is running like new, I almost can't believe the difference in smoothness in both idling and in acceleration.
after doing the latter repair, the engine is running like new, I almost can't believe the difference in smoothness in both idling and in acceleration.
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RhodyRanger
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