I suspect those rocker arm bolts were treated with threadlocker. Warming the bolts with a propane torch will soften the threadlocker, making the bolt easier to remove. You don't need a lot of heat, just a judicious application.

 

Hmmmm, that might've helped aero. Too bad I didn't read that first! I ended up using a long torque wrench, setting it on 28 pounds so I wouldn't crank down too much and having at it. It eventually worked, so now I'm just down to the exaust manifold. I'm planning on either loosening or breaking the four nuts that attach the manifolds to the exaust pipes. Then I'll just pull out heads with the exaust manifolds attached, and detach them later. Reason being, the exaust manifold nuts are completly rusted to the manifold. Hopefully I'll have that done by tonight.

BTW- you're right about WD-40 not really being penetrating. It was the only thing I had though, and its 30 minutes to the nearest auto store. Plus I was wondering if anyone had any particular luck with something I've never heard of before.

 

Hey Tom I was researching some of these old topics and I came across one of your old postings. I have a 94 3.0 and I found what appears to be the same question you posted a year ago.
Here's what you wrote:

"I also found an electrical connector that was not connected to anything. It is from the harness that runs from the coil pack around the back of the engine back to the from of the engine (drivers side) and down the front. It splits near the thermostat. Where it splits there are two coolant sensors here. The unused plug is a single wire and I don't see anything to connect it to. It is very dusty and may not be used at all. Any ideas?"

My question is..did you ever find out what this electrical plug was because I have the same plug not connected to anything. Any idea's?

 

Nope, no replies.

It's still not connected. I guess it is an extra connector for some unused option maybe. I've been using the van as my daily driver until just last week. I finally got my Mazda miata back on the road. Just replaced the engine.

I may switch back and forth some. More room in the Aero but much better gas milage in the miata. You know how the gas prices are not. Now I've got 3 car/vans and only 2 drivers. Nice to have a spare.

Although, my son turns 15 come October.....

Oh NO

 

Thanks Tom. I appreciate the fast response.

 

I notice there were some pictures taken during this process - anyone have them available?

I have a 96 Aerostar with the fluctuating temperature guage - have spent the winter changing the water pump (and PS pump while I was there) and having the radiator checked - finally came down to the head gaskets as a shop showed me the bubbles in the antifreeze.

So, I am going to tackle this myself since I have the heated garage and tools (I am renovating my 1979 MGB), although I am not looking forward to this!

John

 

No pictures. No camera. Wish I had one.

Is yours a 4.0 or a 3.0?

 

Tom,

Mine is a 4.0. Was hoping somone had some pics, just couldn't remember who actually took them. Did you write up any tips or tricks?

 

I wish I had pictures. I did take notes as I went along. I just looked at them. They are kind of short hand notes. But they may be useful. The main thing I would suggest is this. Take step by step notes in a notebook as you go. Bag loose part like nuts and bolts. Put a note in each bag listing what it is and what step it goes with. Then you can reverse the process when you put it back together.
[list=1][*] Mark hood bolt alignment with white out.[*] Disconnect Hood light and gnd wire.[*] Remove hood.[*] Disconnect and remove Battery.[*] Drain Coolant.[*] Remove large air breather tube.[*] Disconnect electrical connector from air filter. Remove filter assy.[*] Remove Weather shield 2-5/16 screws.[*] Remove Belt.[*] Remove Oil fill tube 13mm.[*] Remove Alternator 3-13mm bolts[*] Remove A/C compressor 4-10mm.[*] Disconnect Throttle cable from TB (snap)[*] Disconnect both heater hoses at quick disconnect and engine. Label them.[*] Remove upper radiator hose.[*] Remove 3-13 bolts from coil pack.[*] Remove 4-5/16 bolts from TB Remove TB 1 electrical connector and 1 hose.[*] Remove hose between TB and canister.[*] Remove 2-10mm bolts holding 2 dipsticks. Long bolt for transmission short for oil.[*] Remove 2-10mm bolts from throttle cable bracket.[*] Loosen throttle cable from fastener on manifold.[*] Disconnect vacuum line from tree. It goes the heat/cooling system.[*] Disconnect and tag three vacuum lines from tree.[*] Disconnect 2 electrical connectors and 1 hose from upper manifold. Tagged.[*] Remove 6-13mm nuts from upper manifold.[*] Remove coil pack. 2 electrical connectors.[*] Remove PCV and hose.[*] Remove 7 bolts and 1 stud (10mm) from left valve cover.[*] Remove 7 bolts and 1 stud (10mm) from right valve cover.[*] Remove 6-15mm bolts from rocker arms and remove rocker arms.[*] Remove push rods.[*] Disconnect the 2 coolant sensor units near the front of the lower intake manifold.[*] Disconnect the 6 electrical connectors to the fuel injectors.[*] Disconnect 2 electrical connectors at the top of the engine bay. One connector is black the other is brown.[*] Remove 3-13mm bolts from P/S pump bracket.[*] Remove 1-5/16 screw from P/S pump bracket. Lower pump.[*] Disconnect 2 electrical connectors at the rear of the engine and pull the wiring harness away from engine. I put it where the battery was.[*] Disconnect fuel line from the driver’s side of lower intake manifold. Used adjustable end wrench.[*] Remove thermostat tube 3-10mm bolts.[*] Disconnect other braided/gas line from passenger side of lower intake manifold.[*] Remove 8-10mm lower intake manifold bolts.[*] Remove lower intake manifold.[*] Remove the oil tube bolt from the exhaust manifold to free the tube. I put the bolt back in the hole.[*] Remove 4 15mm bolts from the 2 exhaust pipes. Bolts are under van.[*] Remove 6 10mm bolts from driver’s side exhaust manifold. 2 long bolts bottom front and bottom center.[*] Remove 6 10mm bolts from passenger exhaust manifold. 2 short go to the back top and front bottom.[*] Remove all 16 head bolts and dispose of them.[*] Remove lower intake manifold gasket.[*] Remove driver’s side head.[*] Remove idler arm / belt tensioner. [*] Remove passenger side head.[/list=1]

This may be usefull in that it list bolt sizes. I had Haynes and Chiltons for reference and torq specs. I wish I had elaborated more now that some time has passed but it was enough when I was doing it.

 

Thanks for the list! I have the Ford Service manual on DVD, but havn't explored its level of detail yet. Experience has taught me that notes like yours are a vital necessity no matter what manual you have!