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If you're worried about galvanic corrosion, I don't think either one will cause trouble as long as you change coolant regularly. The steel plug is closer on the anodic table to aluminum, but I would use whatever was available. Paint it if you use steel.

I remember Ford having a TSB on faulty MAF sensor plugs. I'd look very closely at the wire pins that you found loose. Might be a very simple fix...

As XL describes, I'll bet it's the hinge bushings that are worn. Very common since lubing them is often neglected. Dorman makes a kit to repair the hinges, available at good parts stores or online.

A cutoff wheel will cause lots of sparks. I used a reciprocating saw to cut my access Panel, with hardly any sparks. I used a drill on the four corners. Many car mfgs have these panels built in; Ford should have. I used a Bosch replacement on the Explorer, and A Carter on the Ranger a few...

My guess is it's a failed fuel pump, even though you hear it priming. The carbon brushes wear out and give intermittent contact with the commutator.

Good idea about accessing it through the fenderwell. I've replaced 3 of these now on my two Sports. They seem to fail regularly. One started to drop/rise when I was many miles from home, kinda scary...

Is the starter 'draggy'? Might be worn out and drawing too much current. Or the solenoid might be shorted. Also try swapping the starter relay with a similar one in the relay center under the hood.

Never wrestle with a pig. You'll both get muddy but the pig enjoys it...

I wish this one could have been solved. My thoughts are that it was something very simple...

Oops, I confused this with my Jeep nomenclature. Like Turtle said, it's actually an ECM relay, or on early models called an EEC relay. Located in the 'relay center' under the hood. When swapping relays, spray the relay socket with WD-40. This helps clean possible corrosion on the terminal...

Thanks for that tip. A new one for me.

OK I'll bite, what's the penny trick?

Maybe #3 injector left work early...? My OHV did the same at about 150K miles, but I didn't check the fuel trim.

Might be a faulty asd relay, if BOTH spark and fuel are absent... Owners manual will give location.

Because of where it's at, I'd replace it. If it was on the passenger side in a corner, or behind the mirror, then repair could be considered, but that location warrants replacement...

One other thing, try two or three starts without disconnecting the battery, then check for codes. OBD-2 needs at least two successive faults before storing a code... Turn the key completely off, get out of the car and close the door between trys...

IMU, the pcm takes the two sensors; cps and cmp to start. If one or both signals are missing, then the asd relay will shut off power to the coils and fuel pump as a safety measure, so the engine will not start. You can check the cmp signal at che pcm wires; it should show a pulsing 5v every two...

Great job, great pics!

Oops, I missed your earlier post on driving without a working cam sensor. We can rule that out then.

In the first posts, I remember it starting a couple times; shutting down when it warmed, and then no grounding to the 3 coils but 12v to the coil power wire. I know you've already checked them, but I keep thinking of relays, specifically the ASD relay...

I can confirm loss of cam signal will shut down an OBD ll (Jeep). I believe it only times the injectors though, and not spark. Loss of signal will definitely set a code. What is so exasperating is there's no code.

Dave, not much has been discussed about the MAF and IAT sensors, which are the ones you disconnected on the air intake. The IAT increases in resistance the cooler it gets, so you might do further checks on it. Ford also had a TSB on the MAF sensor connector on some models, so could be a problem...

Good job! Muffler installation is "exhausting" work.

I'm pretty sure the tach takes it's signal from the coil grounding pulses. I remember seeing that in a wiring schematic, but I'll double check. Did that erratic voltage on the TPS turn up anything? The O2 sensors haven't been mentioned much. I know some early OBD II vehicles will shut down...

This sounds like the coils are firing since you're getting a grounding signal on the other 3 coil wires....but the sparkplug only fires when the key is released...??? Is this the number 1 plug you're testing for spark? Try the spark test on one of the other coils and see what happens. Might...