Plugs and turn signal

LunarVan · 02-05-2008, 03:43 PM

Hi folks, I'm new to the forum but not new to getting my hands dirty in engine grease, etc...
I've recently changed 4 exhaust manifold studs on the passenger side of my 2000 Lunar Van because it started making a loud chugging noise down on that side. It was a chore to get the broken studs out. I had to remove the whole manifold to get a grip below the broken part, and wrestle with them for several hours before they came free. Putting the new studs in, torqueing them down, replacing the manifold & nuts torqueing the nuts... was easier than getting the old ones off... but it got done.

I decided to crank the engine before replacing the engine cover inside the van, and it sounded just like it had before I did any work to the manifold, chugging away loudly, this time the engine was missing. After contorting myself around with a flashlight and peering into the cramped spaces it became apparent the engine had spit a plug. #6 I think, second from the rear on the passenger side. Now. I've read several articles about the Triton 5.4s spitting plugs, sometimes with massive damage, sometimes not.

After calling the local Ford dealership and getting the advice to inspect for thread damage, use a helicoil kit and be careful putting the plugs back in, and after not finding any kind of diagram to help me out (a diagram which certainly must exist in some accessible Ford library), and after digging out the broken coil pack, plug and connector... AND after talking with a few folks only to discover this is fairly common in the Triton 5.4s, it seems likely there are more than a few folks out there who have found easier ways to do this than the way I'm going about it.

So, I'm asking for help from those folks or anyone who has experience with the Trton 5.4s, especially in E-150 vans. The big question is "what's the easiest way to change the plugs and to install the thread kit for the spit-out plug?"

Also, I've not been able to locate a short in the turn signal on the right side. The rear brake & signal do not work, new bulbs don't do the trick, and different fuses blow when I put a new bulb in the rear socket. Suggestions welcome...

Thanks - great Forum by the way.