Top Issue- 02-05 Ford Thunderbird Ignition Coils COP

biddle

biddle

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2005
I will give my Ford dealer a call and see what they say. Ford gives a 24 month warranty
If it's like the dealer here, they will say bring it in and they will charge you 125.00 for a basic diagnosis. You also have to use Motorcraft parts for the 24 month warranty. One Motorcraft ignition coil costs more than all 8 aftermarket coils. I would venture to guess you could pay a regular mechanic to do the job 3 times for what it costs once at the dealership.

They should trigger a code
*Should* is the keyword there! You said your 2002 only has 21k, miles which means you likely don't drive it a lot.

A/C when that just needed a charge.
A/C systems are closed systems. They shouldn't need to be "charged", so you probably have a leak somewhere, even if very small. They should put dye in the refrigerant and then use a UV light to find the leak.
 
stevedaphotoman

stevedaphotoman

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2002
A/C systems are closed systems. They shouldn't need to be "charged", so you probably have a leak somewhere, even if very small. They should put dye in the refrigerant and then use a UV light to find the leak.
They did do a due test and found no leaks.. They just topped off the system.. I think any A/C system will leak some over 19 years.. I think it took 1/2 lbs last year..

Just stopped down to the Ford Dealer.. It was $900 for all the parts i.e. 8 motorcraft COP's, valve cover gaskets, and plugs.. Labor was about 5 hours at $113.00 per hour. Of course it may not take all 8 COP's and plugs. I will see how it plays out or should I say pays out.. Yes it's a lot of money.. If it was a 2002 Ford focus it would be headed to the metal compactor.
 
biddle

biddle

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They did do a due test and found no leaks.. They just topped off the system.. I think any A/C system will leak some over 19 years.

If you do research, unless there is a leak somewhere, it should not need any refrigerant. It is not consumed like gasoline. A/C units don't need topped off and there are people with well built refrigerators that work for decades.

Of course it may not take all 8 COP's and plugs.

Unless you are on a tight budget, they should all be changed while everything is opened up as many others will tell you. As @Hawkeye mentioned, they gave him back the good ones to use as spares. Back when these were covered by warranty, Ford would only pay to fix the one fouled out and people were constantly in/out of the dealership getting COPS changed out.
 
H
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Jun 24, 2021
Thunderbird Year
2005
Where exactly is the cowl seal located? I ordered one off ebay via the link and could not find where it goes. I replaced the wiper seal easily enough.
Thanks
 
J

JoeMacFQV

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Jun 30, 2021
Thunderbird Year
2002
Hi. Perhaps this should be its own thread, but it seems so related I'm asking here. I'm replacing my 2002 TBird's coils and decided to do plugs based on this thread. They are 17mm and require a deep socket (which I didn't have) so bought a 1/2 inch and 3/8 inch socket. Both sockets are too thick to fit the hole. I've not seen 1/4" deep 17mm sockets, nor anywhere a mention of a special socket for this task. What am I missing ? (I have the cover off and COP off, plug clearly visible... just can't a socket small enough into the shaft/hole to get to the plug).
 
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biddle

biddle

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Hi. Perhaps this should be its own thread, but it seems so related I'm asking here. I'm replacing my 2002 TBird's coils and decided to do plugs based on this
Did you read the previous posts in this thread? Here is page 1 with some install tips, and no you don't need a new thread. This was the right place.

 
J

JoeMacFQV

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2002
Did you read the previous posts in this thread? Here is page 1 with some install tips, and no you don't need a new thread. This was the right place.

Thanks for the quick reply. I took a new plug and it didn't fit any of my existing spark plug sockets, so being a Jaguar based engine I tried metric and found the 17mm fit and said OK. Trying again this morning though and the standard 5/8" socket fits the plug and the hole.
 
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stevedaphotoman

stevedaphotoman

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2002
I just got my bird back from the Ford dealer. I took it on a quick run this morning and it is running smooth as silk.. No hesitation or bucking.. That's after replacing the (8) coil pack all 8 plugs and the 2 valve cover gaskets. I did get 7 of the COP's back. They found PO 303 cylinder 3 misfire.. Both Injector flow test and compression test passed.. They found oil leak in pug wells 5 and 6.. I had them rep[lace all the COPs plugs and both valve cover gaskets.. Hopefully this will cover me for a "bunch" of more years..
 
D

D'Miles

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Jun 14, 2021
Thunderbird Year
2002
Has anyone had experience with any of the following COP components:
Spectra Premium C619 Ignition Coils ( fit and reliability)
Denso 671-8166 Coil-on Plug Boot (fit and capability with other listed components)
NGK 5464 Iridium IX Spark Plugs ( are they good for COP ignitions)

Also, Is this a good combination of components for normal driving in moderate climates ( Oregon) for my garage queen?

I am about to do a complete swap out at 48K miles on my 2002 Thunderbird and your input would be very helpful and thank you
D'Miles
 
biddle

biddle

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Thunderbird Year
2005
Has anyone had experience with any of the following COP components:
Spectra Premium C619 Ignition Coils ( fit and reliability)
Denso 671-8166 Coil-on Plug Boot (fit and capability with other listed components)
NGK 5464 Iridium IX Spark Plugs ( are they good for COP ignitions)

Also, Is this a good combination of components for normal driving in moderate climates ( Oregon) for my garage queen?

I am about to do a complete swap out at 48K miles on my 2002 Thunderbird and your input would be very helpful and thank you
D'Miles
What is used by most members is in post #1 https://forums.fordthunderbirdforum...-05-ford-thunderbird-ignition-coils-cop.5040/
There's no point in pursuing other options, either by the motorcraft COPS or the ones listed in post one which have numerous 5 star reviews.
 
Jeffr

Jeffr

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Jun 25, 2021
Thunderbird Year
2003
Hello tbird owners,
Yesterday my wife and I were on a joy ride and after our tur through the countryside e were going to get back on the highway on the on ramp and lost all power to the gas pedal. Car was still running but very eratic any clues to what the cause could be. We had to be towed home.
 
tbird

tbird

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S

sscharfman

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Apr 9, 2021
Thunderbird Year
2002
Hi guys ! What is the difference between coil and COPS ?

Also, the link for the coils that fits ''better'' (the AD Autoparts I think), showed that they are not in stock anymore ? Anyone as another link to order those coils ? Thank you !!!
No difference. COPS is just an abbreviation for Coil On Plug.
 
2004FordThunderbird

2004FordThunderbird

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2004
Wondering if anyone can comment on this....

I just replaced the spark plugs and coils in my 2004 T-Bird with 63,000 miles (Incidentally, I had to also replace the coils about 5,000 miles/4years ago).

The spark plug wells on the #4 and #8 plugs were filled with very fine dust, which I blew out with the compressor. The covers were securely in place so I dont see how dust can accumulate in those wells. Anyone else encounter this? Any idea where this could be coming from?

Thanks!

Hello tbird owners,
Yesterday my wife and I were on a joy ride and after our tur through the countryside e were going to get back on the highway on the on ramp and lost all power to the gas pedal. Car was still running but very eratic any clues to what the cause could be. We had to be towed home.
Yep. Exact same thing happened to me on the NJ Turnpike. A coil went bad. Car lost power, backfiring. This is a widely known issue. COPs go bad, and often fouls the plug(s) as well. I just had to replace all 8 of mine which was the 2nd time in 4 years and after adding about 5,000 miles. Once replaced engine runs smooth as silk again.
 
D

D'Miles

Member
Joined
Jun 14, 2021
Thunderbird Year
2002
Hello, this will likely be the valve cover gaskets. They get less flexible with the extreme heat of the engine. There are o-rings around each of the spark plugs which will be the source of the leak. New valve cover gasket set is the only answer,not expensive but a bit of labour involved, particularly on the driver's side and involves the fuel line to be depressurized and split at the connection above the valve cover. Try Rock Auto where you have a choice of gasket brands. I've just done mine on both sides. Good opportunity to replace the o-ring at the base of the oil filler tube too. It's not a hard job, just a bit hard to get to some bolts. Good luck Ian
Are the Valve Cover Gaskets for the driver side and the passenger side the same gasket?
Thanks
 
J

jsword47

Member
Joined
May 25, 2021
Thunderbird Year
2003
My car started mis firing during a heavy rain. After a lot of labor i replaced the plugs and ignition coils. The car continued to mis fire. It had to be towed in. Garage said three of the eight ignition coils were bad. I had paid $44 for the set...Lesson learned. Car's good now. COPS.
 
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doug7740

doug7740

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Dec 29, 2014
Thunderbird Year
1955
Since your engine started misfiring during a heavy rain and three coils were damaged, it would lead me to believe that either the Ignition Coil Cover/Wiper Motor Bracket Warranty Extension was never performed, or the new wiper motor bracket seal (5W4Z-54021A46-A) was never replaced.

doug7740
1955 Thunderbird Blue

Wiper Motor Seal.png
 
G

Good Lookin Bob

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2005
Has anyone had a problem with the plastic connector plugs/clips that are used to plug into the coil packs?

I started changing out the coil packs and spark plugs on my 2005 Thunderbird yesterday. Started on the passenger side. Took the dusk cover off no problem. I saw that two coil packs had been replaced by someone else. Then I carefully (and gently) unplugged each plastic connector plug from each coil pack as I removed each of them. I then replaced the all four spark plugs successfully. As I started to install the new coil packs and went to plug in the connector plugs to each of the new coil packs, two of the long plastic clips from inside two of the connector plugs fell out all by themselves. I was very gentle in the removal of the plugs from the old coil packs knowing that someone had been there before. However, now I have two plugs that do not "click" into the new coil packs. The connector plugs fit correctly onto the new coil packs but have no mechanical way for the connector plugs to stay attached to the new coil packs.

Anyone else had this problem? Can the plastic connector plugs be acquired somewhere and spliced into the harness? Or will I have to replace the harness for the entire passenger side of the car?

Or is there some other mechanical way to secure the connector plugs from the harness to the coil packs?

Thanks in advance.
 
biddle

biddle

Forum Moderator
Staff member
Joined
Mar 9, 2003
Thunderbird Year
2005
Has anyone had a problem with the plastic connector plugs/clips that are used to plug into the coil packs?

I started changing out the coil packs and spark plugs on my 2005 Thunderbird yesterday. Started on the passenger side. Took the dusk cover off no problem. I saw that two coil packs had been replaced by someone else. Then I carefully (and gently) unplugged each plastic connector plug from each coil pack as I removed each of them. I then replaced the all four spark plugs successfully. As I started to install the new coil packs and went to plug in the connector plugs to each of the new coil packs, two of the long plastic clips from inside two of the connector plugs fell out all by themselves. I was very gentle in the removal of the plugs from the old coil packs knowing that someone had been there before. However, now I have two plugs that do not "click" into the new coil packs. The connector plugs fit correctly onto the new coil packs but have no mechanical way for the connector plugs to stay attached to the new coil packs.

Anyone else had this problem? Can the plastic connector plugs be acquired somewhere and spliced into the harness? Or will I have to replace the harness for the entire passenger side of the car?

Or is there some other mechanical way to secure the connector plugs from the harness to the coil packs?

Thanks in advance.
Did you purchase these- https://amzn.to/3HH4Qew
 
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