Top Issue- 02-05 Ford Thunderbird Ignition Coils COP

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doug7740
1955 Thunderbird Blue

Doug, I will be removing and re-sealing my cowl and I'm wondering if I need to disconnect the windshield washer tube in order to flip the cowl cover to access it and if so, at what location do I disconnect it? Is there enough slack in the tube so that I don't have to disconnect it at all?

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[doug7740]

After you remove the cowl cover the washer hose can be disconnected at the washer fluid hose connector.

doug7740
1955 Thunderbird Blue

 

[BillCT]

Car has 29k miles and is immaculate. Just developed an intermittent skip but only under load, it runs smooth as silk at idle. I ran the gas down and put in new gas, but no help. The check engine light is NOT on but I scanned it anyway and no codes show up. Wouldn't bad coils or bad plugs throw a code? I hate to start throwing parts like coils and plugs at it without some confidence. Would a plugged cat converter be something to look at, wouldn't that throw a code?
Thanks for any ideas

 

[biddle]

Car has 29k miles and is immaculate.

The car is also 21 years old, 2+ decades old.

The check engine light is NOT on but I scanned it anyway and no codes show up. Wouldn't bad coils or bad plugs throw a code?

Not necessarily, especially during early stages.

I hate to start throwing parts like coils and plugs at it without some confidence.

Pull the spark plugs and examine them. Since the COPS are a common problem as well as a leaking gasket, take a look at one and consider changing these items as maintenance as well- https://forums.fordthunderbirdforum...2-05-ford-thunderbird-ignition-coils-cop.5040 Nobody over the internet is going to be able to tell you for sure.

 

[PLE999]

#1 was dry. #2 was damp. #3 was wet. #4 was dry and didn't look bad. It doesn't seem to be oil but has a smell I can't place. If it is antifreeze, it doesn't smell like any I've smelled before.

 

[doug7740]

The water is entering from the wiper motor bracket seal. Read reply #123 of this post for a detailed explanation- Post in thread 'Top Issue- 02-05 Ford Thunderbird Ignition Coils COP' https://forums.fordthunderbirdforum...hunderbird-ignition-coils-cop.5040/post-83501

doug7740
1955 Thunderbird Blue

 

[jgoedd99]

#1 was dry. #2 was damp. #3 was wet. #4 was dry and didn't look bad. It doesn't seem to be oil but has a smell I can't place. If it is antifreeze, it doesn't smell like any I've smelled before.

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I am relatively new here, but the orange staining is indicative of water under that cover that led to rust, correct? I have seen other posts that looked similar. The fact that they are dry or wet when you inspected them, but all are "orange", would indicate that you have had water under the coil cover at some point in the past. I assume the water eventually evaporated (due to heat) but left behind the rust discoloration. Also water under the coil cover on either side of the engine would ultimately expose all four coils on that side of the engine to moisture once this area gets hot and the water turns to vapor.

 

[PLE999]

I found a 7mm combination wrench at Home Depot for less than $6, but some of the lower screws were still difficult to reach. The driver's side front lower is almost entirely blocked by the tranny dipstick tube. I tried every combination of socket, universal, flexible shaft, etc. and eventually got it out. I just found this on Amazon- https://www.amazon.com/dp/B09BTTCW3Q?tag=thunderbirdforum-20

 

[stevejoliet2003]

2003 26000 after purchasing 5 weeks ago, driving through a strong thunderstorm that night, stopped for fuel, filling with 87 octane, service light came on when I started up. Wasted a week thinking it was fuel. Checking the diagnostic codes with an oil change, local shop wanted 1500 to 2000 to replace coils. After reading your posts, decided to take on the job. For practice I started on the passenger side. As reported the rear lower bolt was the worst. New plugs and coils from Amazon. Was going well until I tried to put coil cover back on, Coils were too high. Not wanting to use a liquid gasket, to make up the gap. Looking at my old coils found they were the original DG529. To replace, get ready to pay a lot more. After installing, the left side only replaced, Service light gone. Did replace cabin filter & wiper seal gasket while waiting to get parts.
Previous post asking about the wiper fluid tube, gently twist the loosened cowl up, to get to both. I had enough tube length, without disconnecting. I attacked the moisture intrusion issue. No signs of oil.

 

[doug7740]

2003 26000 after purchasing 5 weeks ago, driving through a strong thunderstorm that night, stopped for fuel, filling with 87 octane, service light came on when I started up.

From what you posted, I agree that the ignition coils were the cause of the service light illumination. I’m also glad that you are going to purchase the proper coils for the car and not use liquid gasket to make up the gap in the coil covers. Since you purchased your Thunderbird 5 weeks ago you might not be aware that you are putting the wrong octane fuel in your car. As per page 170 of your owner’s manual, your vehicle is designed to use premium unleaded fuel with a minimum octane rating of 91 or higher.


Being a dealer technician for over forty years I can’t tell you how many times I have seen vehicles with drivability issues, and in worse cases, engine damage because the customer decided to use a cheaper fuel.

Higher octane fuels are required or recommended for engines that use a higher compression ratio. Increasing pressure in the cylinder allows an engine to extract more mechanical energy from a given air/fuel mixture, but requires higher octane fuel to keep the mixture from pre-detonating or knocking. In these engines, high octane fuel will improve performance and fuel economy. Using a lower octane fuel than required can cause the engine to run poorly and can damage the engine and emissions control system over time. Many newer vehicles can adjust the spark timing to reduce knock, but engine power and fuel economy will still suffer.

doug7740
1955 Thunderbird Blue

 

[Bigdog1949]

2002-2005 Ford Thunderbird and Lincoln LS have a widely known issue with Ignition coils going bad and also fouling out spark plugs causing misfires
. Just by replacing these components, you may be able to bring new life to your engine!

At the time of this post, 59.30 for an entire set of Ignition Coils! Can't beat that! If you have a 2002-2005 Ford Thunderbird I would buy these just to have on hand because of the history of these going bad! Don't forget to order 8 spark plugs too because the coils foul them out!

Many people have had success with the coils above, but if you are looking for a brand name check out the Denson and NGK Coils. Click here to buy them on eBay.
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UPDATE April 2020
Here is the link for the updated part as of 04/2020 that fits better with the valve cover- https://amzn.to/31CezPd previously everyone was ordering parts galaxy which works, but is a tight fit. You can also get NGK and Denso name-brand ignition coils here.

There is a post below with installation instructions- https://forums.fordthunderbirdforum...hunderbird-ignition-coils-cop.5040/post-35040

Important- You may also have a problem with your cowl seal, wiper seal or valve cover gasket, which is causing the coils to fail! You can read more about that in this post. If you have coils problems after a few days/weeks/months it's likely not the coil, but an additional problem.


What you need to buy
1- Ignition Coils (Amazon Purchase Link)
2- 8 Spark Plugs (Amazon Purchase Link)
3- Dielectric grease (Amazon Purchase Link)
4- Valve Cover Gasket (Amazon Purchase Link) (EBay Purchase Link) (optional but highly recommended while doing the job)
5- If you need the deep & shallow 7mm sockets, here is a pack with both (Amazon Purchase Link) Also, this 1/4" swivel socket will help you get to the one hard to reach. Note: 1/4" drive makes the job easier! Some owners have reported this tool is also good for reaching the back one- https://www.amazon.com/dp/B09BTTCW3Q?tag=thunderbirdforum-20
6- This type 7mm wrench will make the job easier



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I just replaced my valve covers ,no big deal ,took a while ! , but I would like to tune up the designer of the engine compartment !

 

[bayfeet]

2002-2005 Ford Thunderbird and Lincoln LS have a widely known issue with Ignition coils going bad and also fouling out spark plugs causing misfires
. Just by replacing these components, you may be able to bring new life to your engine!

At the time of this post, 59.30 for an entire set of Ignition Coils! Can't beat that! If you have a 2002-2005 Ford Thunderbird I would buy these just to have on hand because of the history of these going bad! Don't forget to order 8 spark plugs too because the coils foul them out!

Many people have had success with the coils above, but if you are looking for a brand name check out the Denson and NGK Coils. Click here to buy them on eBay.
View attachment 24204View attachment 24205

UPDATE April 2020
Here is the link for the updated part as of 04/2020 that fits better with the valve cover- https://amzn.to/31CezPd previously everyone was ordering parts galaxy which works, but is a tight fit. You can also get NGK and Denso name-brand ignition coils here.

There is a post below with installation instructions- https://forums.fordthunderbirdforum...hunderbird-ignition-coils-cop.5040/post-35040

Important- You may also have a problem with your cowl seal, wiper seal or valve cover gasket, which is causing the coils to fail! You can read more about that in this post. If you have coils problems after a few days/weeks/months it's likely not the coil, but an additional problem.


What you need to buy
1- Ignition Coils (Amazon Purchase Link)
2- 8 Spark Plugs (Amazon Purchase Link)
3- Dielectric grease (Amazon Purchase Link)
4- Valve Cover Gasket (Amazon Purchase Link) (EBay Purchase Link) (optional but highly recommended while doing the job)
5- If you need the deep & shallow 7mm sockets, here is a pack with both (Amazon Purchase Link) Also, this 1/4" swivel socket will help you get to the one hard to reach. Note: 1/4" drive makes the job easier! Some owners have reported this tool is also good for reaching the back one- https://www.amazon.com/dp/B09BTTCW3Q?tag=thunderbirdforum-20
6- This type 7mm wrench will make the job easier



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I noticed the price for ngk & denso are significantly higher than the deal in 2016. Are the ena coils just as good for 42.00? Do the ngk plugs need to be gapped? Ed

 

[jim48]

I'm considering buying a t'bird 02 thru 05 not sure on what year but this problem I have been reading about coil packs going bad because of oil or water leaks is concerning, how often do they need to be replaced? If from an oil leak from valve covers and the valve cover gaskets are replaced how long before they leak and short out again? Can this repair be done in my garage?

 

[biddle]

I have been reading about coil packs going bad because of oil or water leaks is concerning,

Why would this be concerning? All cars, especially 20+ year old ones, with a valve cover can have a valve cover gasket leak that fouls out spark plugs, COPS etc. The problem is simple: when people replace the spark plugs and COPS on any car that has a valve cover and a leaking gasket, the problem reoccurs. What is bizarre, for some reason over the years, people with Thunderbird have decided to blame the car. LOL

Start reading on Post #1 if you want to learn about this topic- https://forums.fordthunderbirdforum...-05-ford-thunderbird-ignition-coils-cop.5040/

 

[bayfeet]

Bought ena coils and ngk plugs based on the link. Was not throwing any codes but the car seemed to be sluggish. Tough getting bottom 7mm bolts near firewall on both sides. What a difference! I guess after 20 years the plugs and coils were tired. Acceleration will snap your head back now. Thanks for all the info!

 

[H-Town 02 T-Bird]

I just bought my 2002 bird this fall my mechanic said the one on the second bank went bad because of a small oil leak in the valve cover gasket. so I had him replace plugs and both gaskets.He said that will take care of it.

This is true. Our 02 with 34K miles started sputtering. Didn't look for a code, just took it to an old friend who's a Ford man. They found a leak in the gasket which was causing the problem in cylinder 5. He replaced the gasket, the coil and plug. It was thundering once again. I'll get some time in the new year and go ahead with the other bank. This time gasket, coil packs, and spark plugs all the way around.

 

[Edzooom]

2002-2005 Ford Thunderbird and Lincoln LS have a widely known issue with Ignition coils going bad and also fouling out spark plugs causing misfires
. Just by replacing these components, you may be able to bring new life to your engine!

At the time of this post, 59.30 for an entire set of Ignition Coils! Can't beat that! If you have a 2002-2005 Ford Thunderbird I would buy these just to have on hand because of the history of these going bad! Don't forget to order 8 spark plugs too because the coils foul them out!

Many people have had success with the coils above, but if you are looking for a brand name check out the Denson and NGK Coils. Click here to buy them on eBay.
View attachment 24204View attachment 24205

UPDATE April 2020
Here is the link for the updated part as of 04/2020 that fits better with the valve cover- https://amzn.to/31CezPd previously everyone was ordering parts galaxy which works, but is a tight fit. You can also get NGK and Denso name-brand ignition coils here.

There is a post below with installation instructions- https://forums.fordthunderbirdforum...hunderbird-ignition-coils-cop.5040/post-35040

Important- You may also have a problem with your cowl seal, wiper seal or valve cover gasket, which is causing the coils to fail! You can read more about that in this post. If you have coils problems after a few days/weeks/months it's likely not the coil, but an additional problem.


What you need to buy
1- Ignition Coils (Amazon Purchase Link)
2- 8 Spark Plugs (Amazon Purchase Link)
3- Dielectric grease (Amazon Purchase Link)
4- Valve Cover Gasket (Amazon Purchase Link) (EBay Purchase Link) (optional but highly recommended while doing the job)
5- If you need the deep & shallow 7mm sockets, here is a pack with both (Amazon Purchase Link) Also, this 1/4" swivel socket will help you get to the one hard to reach. Note: 1/4" drive makes the job easier! Some owners have reported this tool is also good for reaching the back one- https://www.amazon.com/dp/B09BTTCW3Q?tag=thunderbirdforum-20
6- This type 7mm wrench will make the job easier



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I found, that out of all them that the NGK coils had the highest heat index of all the other coils I researched, with heavier coils and stronger epoxy and better construction than the rest of them.

 

[gregl32]

Did you change the Coils also? Are you getting check engine light? Even if no light, check for codes using a reader that can check all the modules for any code even if no light (yet)

 

[gregl32]

Have a check engine light and the only thing that popped up on scanner was the throttle body but once I put the new one in there was no more codes

Did you change coils? Was it running rough before? Maybe the connectors to the coils need checked? Maybe coil connectors got connected to wrong coils? Maybe fuel injector issues? There could be more codes that don't turn on check engine light. Plugged exhaust system (e.g. cat converter)? A constant misfire normally causes Check Engine light but if car dies too fast it might not light.
Even though new, could be bad filter, bad fuel pump, bad throttle body, etc.
Usually #1 reason for rough running are bad coils.

 

[jneuenburg]

A quick tip for those changing coil packs. If this was mentioned in this thread, please excuse the redundancy,

A very handy tool to have is a 1/4 inch drive, 7mm swivel socket. With the swivel and socket combined it is shorter and handier than using a regular socket and a swivel. With a six inch extension it really helps get the bolts out at the firewall end. The socket shown here has a joint that is tight enough so it will stay at the angle you set. That helps the socket find the bolt head. For example on the passenger side using the extension, you push it past a wiring harness, put the socket near the bolt, and by hand tilt it so it lines up with the bolt. Then push it on. If the socket is loose so gravity makes it flop down, it is a little harder to line up.

The brand I bought online is Tekton.