Well, I went and replaced my front shocks today. Not such a big deal. Had to get out the torches to cut the top nut off both of them. No other way to get it off. You should have seen the flames! LOL!

I also replaced my front brake pads. Not a big deal.

Then I wanted to replace my spark plugs. Yes, WANTED! So I thought I would replace the wires and cap and rotor at the same time. Well, I started with spark plug number 5. I was bound and determined to get it out! Guess what? Only took me 12 minutes to get it out and a new one back in! I don't see what the big deal is. Not something I would want to do everyday but wasnt that bad. So anyone who wants to replace your plugs, go ahead....its not THAT bad. To replace the wires, plugs, cap and rotor only took 1 hour and 45 minutes. Not too shabby I thought.

Spark plugs: $20 canadian
Wires: $65 Canadian
Replacing # 5 spark plug in 10 minutes: PRICELESS!

BTW..... the van was a 3.0 litre

-Matt

 

Good job! I'm about to change plugs and wires on my '95 4.0 Aerostar. Could you please explain a bit on how you went about doing it?

TIA

 

Well, I am assuming that the 4 litre and the 3 litre and almost the same setup...yours may be a little more cramped. Also, mine was a 1989 but that shouldn't make that big of difference. Anyways, I used a 3/8" drive ratchet (I thought a 1/2" drive drive would be too big). I believe 5/8" deep socket, a 3" extension,a 6" extension and a universal joint for the hard to reach places.

I also bought spark plug wires because I wanted to replace them. I would recommend you at least buying them and having them on hand because when I took my old wires off a couple of them came apart when taking them off. At least if your old wires come off fine and look to be in good shape you can return them.

You also have to take off your front tires and support it with jackstands. Make sure you have a trouble light as well. You also have to take off your inside engine cover. At least that's where my distributor was. Yours may be different.

I started with the number 5 spark plug because I heard it was the hardest. Basically, just take out your old spark plugs one at a time and replace them and put the wire back on. It took me one hour and 45 minutes to replace all the plugs, wires and the distributor and rotor. Not too bad for my first time I thought.

If you have any other questions just ask....I will try to help you out.

Good Luck!

-Matt

 

> I'm about to change plugs and wires on my '95 4.0 Aerostar

On this vehicle (I own one) you use almost the same technique as a 2.9 Ranger/BII.

Jack the Aerostar up in the middle near the control arms and put the jack under the pivot/hinge of the control arm or on the subframe next to it. Jack stand for each side. The idea is to drop the control arms so the wheel drops from the wheelwell.

Change the spark plugs from inside the fender, except #3, which is easier from underneath. While there in the fender well, lube the upper ball joint.

Put a liberal amount of anti-seize on the plug threads and di-electric grease inside the spark plug boots.

After a week of driving, retorque the spark plugs. They will loosen up sometimes. It is very hard to "torque" them to factory specs and if you do them too hard ... well lets just say you do not want to.

Get the Motorcraft set of plug wires. The aftermarket wires from Autozone and such are real cheap with thin wall insulation that rips easy. Especially when putting them into the spark plug loom. In the long run you will not save the $30 extra the Motorcraft ones cost, especially if you get driveability problems from the wires.

 

Thanks for the input guys. I wil be changing the plugs and wires this week-end. I will post the results.

TIA

 

I found that an assistant is a great help with removing & installing the plugs - and alows the job to get done without removing tires. On the 90 aerostar, I can remove & replace all plugs on the driver side - although I have to use a socket & open end wrench to get the one nearest the driver. To get at the passenger side plugs, one person sits in the passenger seat and 'guides' the plug & socket into the correct place while the other (through the wheel well) holds the handle & applies the torque. An assistant also makes the plug wire routing easier too, one person inside the van & one outside the van.
Easy less than 1 hour with help.

 

Hi Guys...finally replaced the plugs and wires today with the help of a friend and I must say I have a few bruised knuckles. It wasn't too bad you just have to be really patient and take it one plug at a time.

My friend routed the wires from inside the van while I removed plugs and wires.

Took us about 2 hrs because we had to soak 2 plugs with penetrating oil as they refused to budge initially and prayed that they didn't break.

Also changed the o2 sensor while we were at it. The old sensor was barely screwed in and I used my bare hand to remove it after a couple of turns...so that's where that exhaust leak was coming from!?

 

Good job! I went out and bought a pair of mechanic's gloves from my local Canadian Tire before I did them. That sure saved my hands from being cut up. Clean up was also MUCH easier, not so much grease. The best $35 I spent! I finished my plugs and went to start the van and it start up but kept stalling and thought "Oh great, which plug or wire did I not install correctly!?!?" Ended up being a vacuum line that had come of during installation. That was basically my only problem. Good luck to anyone else out there that does them....trust me I did it by myself and it only took me 1 hour and 45 minutes. Not as hard as people make it sound.

-Matt