engineering complaint
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From: oakland
engineering complaint
Does anybody know why Ford engineers chose to use security torx bolts for the MAF, reversed allen bolts for the fuel regulator and 5.5mm hex bolts (instead of allen) for the ignition module?
( I won't even mention the spark plugs-but while I'm at it
,I removed my outside blower housing for the evaporator, and had clear sight ot the last two passenger plugs. But they still could not be removed without "the hands of a chipmunk, the strength of a gorilla and the skin of an alligator").
Please, someone enlighten me.
( I won't even mention the spark plugs-but while I'm at it
,I removed my outside blower housing for the evaporator, and had clear sight ot the last two passenger plugs. But they still could not be removed without "the hands of a chipmunk, the strength of a gorilla and the skin of an alligator").Please, someone enlighten me.
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Since the Feds regulate the emissions process, it would be reasonable guess that manufacturers must comply with some arcane 'security' measures to prevent owners from tampering with the system. Similar to those plastic restrictor caps they used to put on carburetor adjustment screws.
The passenger side plugs can better be accessed from under the van. The last one is a bit tight but not impossible to reach. I use a plug socket (3/8" drive) that has a hex-head around the outer end. I can put the socket on the plug and use an open ended wrench on the hex-head portion to loosen the plug and fingers to turn it the rest of the way off. I also have a thin-wall, deep metric socket (Craftsman/Sears) that is short enough to use with a 3/8" drive breaker bar to remove/install that last plug.
The passenger side plugs can better be accessed from under the van. The last one is a bit tight but not impossible to reach. I use a plug socket (3/8" drive) that has a hex-head around the outer end. I can put the socket on the plug and use an open ended wrench on the hex-head portion to loosen the plug and fingers to turn it the rest of the way off. I also have a thin-wall, deep metric socket (Craftsman/Sears) that is short enough to use with a 3/8" drive breaker bar to remove/install that last plug.
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From: Southern California
To get access to those last two plugs, I removed the /AC compressor, the power steering pump, the alternator, the radiator, the fan, and the intake manifold. Then you have a clear shot at them. Of course I'm just jesting, but it's not too far from the truth, is it? 
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I do my plugs in about 40 minutes with a cigarette break included.
I do the plugs from under the van and through the wheel wells.
And as aerocolorado says, that last one is done with a hex plug socket with an open ended wrench.
I used a small pair of vise grips to take the "NON"tapmper torx screws out of the MAF sensor and replaced them with allens.
I do the plugs from under the van and through the wheel wells.
And as aerocolorado says, that last one is done with a hex plug socket with an open ended wrench.
I used a small pair of vise grips to take the "NON"tapmper torx screws out of the MAF sensor and replaced them with allens.
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Mojo Hobo here
Like aerocolordo & Berry said it can be done but boy did I curse Ford engineers and lost some blood trying to fit my hands in those places.I also changed the screws on my T.P.S. sensor to allen screws,believe me you wouldn't believe how I got one of the screws off of it,too long to write.If you have time, patience and some good tools it can be done,keep us posted.As for the engineers,no comment.
Like aerocolordo & Berry said it can be done but boy did I curse Ford engineers and lost some blood trying to fit my hands in those places.I also changed the screws on my T.P.S. sensor to allen screws,believe me you wouldn't believe how I got one of the screws off of it,too long to write.If you have time, patience and some good tools it can be done,keep us posted.As for the engineers,no comment.
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Mojo Hobo here
You are right not far from the truth,what happened to the days when you could change plugs in the rain with the hood closed L.O.L.
You are right not far from the truth,what happened to the days when you could change plugs in the rain with the hood closed L.O.L.
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Originally Posted by copper_90680
To get access to those last two plugs, I removed the /AC compressor, the power steering pump, the alternator, the radiator, the fan, and the intake manifold. Then you have a clear shot at them. Of course I'm just jesting, but it's not too far from the truth, is it?
Mojo Hobo
Last edited by mojo hobo; Jul 21, 2004 at 11:06 PM.
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From: Mitchell, SD
Originally Posted by psyche
I'm actually not trying to change the plugs right now, but thanks for the "how to". This thread was more about the frustration of working on new vehicles. 
! It makes you think creative ways to remove things without putting down the cash for that one time use special Ford tool. Then I replace with hex head bolts, The rest are too much of a PIA to remove in the future after they have rusted in some.I think that aerocolorado is right about Fed regs.
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From: oakland
I would disagree with the two folks who suggest it's a Fed requirement to have these tamper proof systems on those three components since all three-MAF,fuel reg., and ign. module must be connected for the engine to run. It's not like in the early years of pollution devices when you could remove or modify the component and the car would run stronger. Things are different now;everything is connected to the CPU and thus everything must be attached. But one thing that is not too different is sometimes being "forced" to visit the dealership @ $115 an hour.