I purchased a new used van 3 weeks ago and I am checking all critical known failure points. I pulled #1 plug. First, I blew the well out with compressed air. Next, I sprayed the well with penetrating oil made from 50/50 acetone/ATF. I easily removed the plug. I inspected the plug and it appears that it's not the original plug. The van has 94,000 miles on it. It has a consistent maintenance history over the life of the van.

The spark plug on the left is the #1 plug that I pulled next to a new plug. I put nickel anti-seize on the plug threads and set the torque wrench to 24 ft pounds. I squirted dielectric grease in the boot. The COP is an after-market COP. I have 5 new COPs. We are leaving on a 6000 mile plus cross-country camping trip. I will install 8 new plugs when I return. I plan on putting the torque wrench on the #5 plug set @24 ft pounds.


I changed the oil and installed a Ford oil filter. The coolant has about 10000 miles and was change about 3 years ago.

I flushed all the brake fluid. I ordered rear brake pads.

Installed new Bilstein rear shocks. It had fairly new Ford OEM shocks. I will replace front with Bilsteins later this summer.

I have a new belt pulleys for the drive belt system.

I replaced air filter.

New fuel filter waiting for removal tool.

I tried to remove the differential fill plug was not successful. My mechanic will remove cover and install new fluid for $60.

5 gallons of ATF arriving Saturday night for a fresh flush.

It has a 2017 Napa Premium alternator.

 

6000 mile? Dang. Make a post on your progress of the trip and how the van does and pics of places you visit and people you meet. Cool stuff.

 

I will post photos and updates. We have been doing this with my 2 boys and wife since 2005. We started in a 1991 Honda Accord Wagon. We moved on to a Subaru Outback and outgrew that. In 2012, we bought an old E150 van for $1000. Next, someone donated a 2004 extended E350 diesel that we used for picking produce at a farmers market to donate to a non-profit. This was by far the most expensive vehicle to operate and we sold it and bought an extended 1998 E350 gas van. We missed the power windows, locks, and comforts of the diesel. We sold both the E150 and E350 within a week of each other picked up a cherry 2003 with 94,000. It's a lot of work doing the simple camping conversion. Solar, beds, storage solutions, and thoroughly checking the rig.

Here;s a rough outline of our voyage.


Big family voyage 2020

 

Good gravy CoolFeet I'm gonna nickname you Lewis & Clark now! So a few thoughts about your post here.......

The #1 plug you shows what I've thought and opined about since first learning the modular motor's plugs can go at least 100K before needing changed--poppy **** I say. I do the 24 ft/lbs torque wrench, nickel-based anti-seize and closely inspecting the boots about every 50K miles. I want to think this is better for overall performance but more importantly is at that interval (along with anti-seize) plugs don't resist changing next time out.

Transmission flushing is a wise idea---I'm a firm believer in Mark K's procedure and will never again do the pan drop, change filter and add 5 qts AFT again. All things considered for a driveway DIY mechanic the flush is so much less messy and avoids spilled fluid too.

Good stuff CoolFeet---you sound well prepared for this upcoming Corps of Discovery Expedition!

 

JWA, are saying that I should change the #1 plug? Please advise. I can easily reach 4 plugs before departure. Possibly 6.

 

Typically if I pull a plug it gets replaced unless it has less than 20K or so miles. In your case the #1 looks a bit more worn than I would allow but if you're not changing all at the same time maybe re-install the existing part and change them all after your upcoming odyssey.

 

@JWA, good call on replacing all at the same time. I sent the photo to mechanic buddy in Louisiana and suggested the same. By looking at the photo, he said it probably has less than 10,000 miles and advised waiting until I get back.

I am training my 19 year son basic automotive repair and and he's getting good. He installed the new stereo system yesterday. I like having him around when putting the serpentine belt back on because he has small hands, arms, and fingers. Long story short, we replaced the 2 pulleys and one of us installed the tensioner pulley backwards! It screeched and complained on startup. We pulled everything apart again and noticed the pulley was rubbing agains the engine. I laughed and he said "What's wrong?" I said you will see. I reinstalled the pulley correctly and the noise disappeared. I was unable to find a Motorcraft replacement tensioner pulley and ordered a Gates. After installation, I felt a slight wobble. I told my son to feel it and he said he would never have felt or checked it. I mentioned that checking everything no matter what your profession is a good habit. He is studying computer engineering. I mentioned mistakes like we just made can and will cost you your job. We reused the old pulley as Ford says it's good up to 150000 miles.

We had a speaker phone conversion with my mechanic friend in Louisiana over a different issue and he told my son the same thing-"Pay attention to the details and you will go far in life." My son is easily distracted over his phone giving him social media updates. Since he is broke and cannot afford phone service, he has a voice only plan and does not get internet unless connected to WiFi. My wife frequently pulls the plug on WiFi to keep our 2 teenage sons from getting too distracted. It's funny to see them panic when she disables the modem. They both know better than to reconnect service as the wrath of Mommy is sever!

 

While checking the torque on the #5 plug, I noticed it had a MasterPro aftermarket coil pack. It look fairly new and in good condition and said "Made in Taiwan". That's more comforting than "Made in China". At least the previous owner had the sense to use good replacement parts. I replaced it with a new Motorcaft COP since I had the boot off. As near as I can tell 2,3,6,&7 have MotorCraft COPS. The only way I will know is by pulling them when I change all plugs upon my return.

 

Well not getting into guiding youngsters through life but we ALL could and would do much better by simply using a phone as a f'ing phone. I know that makes me sound like a grouchy old man (which I am) however I'll compare my life against anyone addicted to "updates" and fare just as well, perhaps a bit better as I can concentrate on a job at hand. I have two friends who live on their phones,one who works for me on occasion who does leave his phone in the truck while we're on a job. The other cannot have a 2 minute conversation without a pause to check some annoying dinging on his "smart" phone---gets tiresome dealing with that nonsense...........but I am distracted now too it seems..................

I use nothing but Motorcraft everything and with the prices of authentic COP's hitting about $27 each including boot and spring there's just no reason to use any other brand. (On that note here's a Youtube link how to assure you have genuine Motorcraft COP's etc:
I've downloaded and printed off various serpentine belt routing diagrams for my three different E-Series with the same 5.4 engines---those are in sheet protectors and part of my carry along file of vehicle information. (Serpentine Belt Diagrams) Fuse charts, a complete EVTM for whatever year and an aftermarket alarm programming instruction page in case that's ever needed are also part of that folder. BTW those are all printed copies as their batteries don't die or memory wiped out without warning........... Distracted again dammit

Replacing the serpentine belt becomes easier to do each time you do it and while I've never had one break even after 150+ K miles its a good idea to check it each plug change, replace the belt at 100K miles would be my best advice.

Good stuff CoolFeet!