Thanks to the experts here for monitoring and answering all questions, especially biddle. I have a few comments and tips after installing four coils and 8
plugs in my 2003 yesterday. I think one problem I had has not been discussed on this thread. I also have a question. Some of this is about tools.
The job was easier than some say. Anybody who is familiar with tools and doing easy stuff on cars can do it but having certain tools helps a lot. Yes, a 1/4 drive ratchet with
7mm socket is mandatory and a
7mm combination wrench is good to have. Extensions as shown in the picture below are what I used. The tools at the bottom were for the coils and the ones above were for the
plugs.
I used the handled driver but it wasn't necessary. Some bolts needed the ratchet to loosen. A small magnet like on that screwdriver is nice to have. The circled tools are the
7mm sockets I used. The one on the extension is a swivel socket. It occupies LESS SPACE than a universal joint adaptor with socket and is REALLY HANDY for getting to those lower rear cover bolts, and for a couple of the coil bolts. I DID NOT REMOVE OR LOOSEN ANY
PARTS TO GET ACCESS TO THE BOLTS ON EITHER SIDE. This is the benefit of using the right tools. I did not need to move a big
wiring harness out of the way to get to the lower passenger side bolt. I could work the extension with swivel socket behind it, and unlike a universal joint adaptor and socket which flops around, mine could be pre-set at the proper angle and guided the last inch or two to the bolt. For reinstallation of that one I used a long mechanics flex-shaft magnet. Worked it behind the harness with left hand pulling harness away from the metal with my right, then put the bolt head on the magnet, guided the magnet and bolt to its target. Once in the hole the magnet can be pushed to the side and withdrawn. Then come back with the extension and swivel socket. Easy peasy. Another installation trick could have been magnetizing the extension and socket to hold the bolt. But the bolt can be inserted by hand if one is patient. By the way on my engine the lower driver side bolt is shorter than the others and works fine.
Standard sockets are a little quicker and more stable than the flexible types when no clearance problems. I found using the short and long extensions at different times worked well, and even joined together a couple times. I did not use a deep
7mm socket.
Here is the Tekton SHD08107 swivel socket. Well made and I like how it stays at whatever angle you put it:
Some of the folks talked about carrying a spare set of coils in their trunk. Only a couple mentioned having the tools! Important! This little bugger will be included in my trunk tool set, as will
dielectric grease. Maybe a spare bolt or two.
I thought a previous mechanic had stripped a cover bolt or it's fitting. A middle one. It turned but didn't come out. I couldn't pull it out with pliers. So I removed all other bolts so the cover could be flexed up at the front using a lever. Fingers might have worked, its plastic. This put upward pressure on the bolt so it came out. Turned out the steel female fitting came out with it! It had come unglued, maybe it stripped while over-tightening. It happened on two other fittings. Here you can see a fitting above the coil, and the cover shows a fitting that came off with the cover and bolt.
Note the fitting is knurled where it sits in the plastic manifold. These are glued or molded in during manufacture. So I needed to re-glue it. It and the bolt were stuck to the cover, so I put the knurled
part in a vice and unscrewed the bolt. Then noticed the fitting has two expansion/ contraction slots.
Obviously I wanted to make the thing bigger so it was a press fit back into the manifold. So I put in a vice and tapped with chisel and hammer to open the slots wider. Then I glued them in. I used a two-
part thread repair product on one, and blue Loctite on the other two. After curing, all bolts took installation torque. Next time I will use epoxy or Crazy Glue. Anyway we'll see what works long term. Moral of story is don't tighten the bolts too much.
I did the driver side because my mechanic's
scanner said #5 was misfiring. I had all 8 coils on the shelf since reading this thread a year ago. I replaced all four on that side and when looking at the
spark plugs I noticed a gap of .046. I was told gap should be .041. I have heard a big gap is hard on coils and this was 20% too big, So I put new Iridiums in it and decided to replace the other four
plugs, thinking if they are worn that could hurt those coils. I don't know. I didn't replace those coils because I am curious how they last, and will keep a set with tools in the trunk for when travelling. The passenger side is a little quicker to do because fewer tool changes due to
parts in the way.
BTW in 2021 I had purchased the recommended (here) ENA DG515 DG509. These are about 1/8" longer than the Ford ones that came out. So like the aftermarket ones you all talked about many years ago. Cover seated perfectly. Do the 2003 and later covers offer more clearance than 2002 or are these upgraded covers? I am going to buy another set and it looks like the latest and greatest is now the DG515 G-8 from AD Auto
Parts via
Amazon. The picture shows a connector the same as Ford. Shorter. Hope they work!
John
