2000 Explorer 4.0 OHV spark plug wire removal

[NaggiDonkee]

Recently I got a Check Engine light pop up, and went and got it scanned. It was a cylinder 3 misfire. So naturally I went and got new plugs and wires. I was able to get the passenger side done with no problem. The driver side is a whole other story. If anyone is familar with replacing wires on this engine, I would greatly appreciate some feedback, cause it looks very time consuming. I don't think it is as easy as simply fishing the wires underneath in intake manifold. I would think it would have to be removed. Cylinder 5 plug wire (one closest to the radiator) has a "stay" clip the is right beneath a metal pipe(not sure what it does)which leaves no room to remove it. I have a Haynes manual, but it says nothing about removing anything to gain access to the plug wires.

The CEL light was cleared, so looks like I fixed the misfire, but I would like to finish the rest of them.

 

[NaggiDonkee]

Appears that someone already had trouble with this already
http://www.explorerforum.com/forums//showthread.php?t=204298

Hopefully I won't have to do this
http://www.explorerforum.com/forums/showthread.php?t=171819&highlight=ohv+intake+gasket

 

[NaggiDonkee]

LOL...and this guy!!

http://www.explorerforum.com/forums/showthread.php?t=181929&highlight=backhoe

You think something so simple could be so easy!

 

[ssobel80]

I know it looks like a problem but it is really simple to fish the wires through. All I needed was a set of needle nose pliers. Also on the OHV at least, it is very easy to get to the spark plugs from the top. No need to go through the wheel well like everybody claims is the only way to do it.

 

[koda2000]

why not just cut the old ones off and route the new ones where you can get at them. if necessary buy some plug wire looms/clips to hold things together and out of the way.

 

[ssobel80]

why not just cut the old ones off and route the new ones where you can get at them. if necessary buy some plug wire looms/clips to hold things together and out of the way.

Why not put them back the way they were designed to go? It is simple. And won't be done half-ass backwards it will be done correctly

 

[koda2000]

Why not put them back the way they were designed to go? It is simple. And won't be done half-ass backwards it will be done correctly

well, i guess it depends on how much time you're will to spend on it. it's only a spark plug wire after all. if you can install it the right way in a reasonable amount of time, great. i don't have an OHV V6 engine, so i can't offer specific advise on how to do it the "right way" but if it means having to remove a major engine part to do it, screw that. maybe someone with an OHV engine can be more helpful than you or i.

 

[ssobel80]

well, i guess it depends on how much time you're will to spend on it. it's only a spark plug wire after all. if you can install it the right way in a reasonable amount of time, great. i don't have an OHV V6 engine, so i can't offer specific advise on how to do it the "right way" but if it means having to remove a major engine part to do it, screw that. maybe someone with an OHV engine can be more helpful than you or i.

I do have an OHV and I did replace the spark plugs and wires about 2 weeks ago. So yes I do know that it can easily be done the correct way! You do not have to remove the plenum, there is room to fish them through. I used just a pair of needle nose pliers. The only thing I did a little different was change the route of one of the wires through the plenum cause it made it easier. (I believe it was the number 5 wire, I may be wrong. It is the longer one)

The only other way to run the wires would be across the top of the plenum which is not the most ideal situation. The other option would be to replace the ohv wires with sohc wires, I believe they are longer and can run around the back of the motor. This second option would work and could be done correctly. My opinion is as we all know our explorers are very picky about there electrical system. They seem to only work well with the factory set up. Why would you want to change that!

Koda, are you serious saying it is only a spark plug wire! I don't know who you are or what you do for a living but I sure as hell hope you are not a mechanic of any kind. Only a spark plug wire, you have got to be joking. How the hell is your car going to run if you even slightly damage ONLY a plug wire.

 

[Turdle]

As long as the wires are routed out of harm's way--( heat or friction on another part) , then it is the "right" way.

No need for questioning skill level here. As Koda said, it's just a spark plug wire

 

[lugnuts55]

I have changed the wires on my 96 EB 4.0 OHV and on the driver's side, I disconnected the connecters on the IAC, TPS and anything else in the way. When you get the wires changed, the harness will fall back into place so you can figure out where everything goes.

I hope this takes care of the misfire for you.

 

[swshawaii]

Why not put them back the way they were designed to go? It is simple. And won't be done half-ass backwards it will be done correctly

Why do you believe Ford "designed" to route the OHV's wires this way?
Design flaws are common, aren't they the reason for TSB's and recalls?

 

[ssobel80]

Why do you believe Ford "designed" to route the OHV's wires that way?
Design flaws are common, aren't they the reason for TSB's and recalls?

I believe it may have been to keep them in a safe and protected area away from heat and moving parts. It makes the most sense to put them where they will be protected.

Again it is not very hard to put them back the same way. They will fit and there is plenty of room.

 

[TsherryUSA]

Old thread, I know. Did my plugs and wires today. Everything I'd read said that the passenger side was hardest. I started with the drivers side and found running the new wires was the bulk of the day's work. Was wishing I'd had longer needle nose pliers. I ended up using some picks/hooks to fish the plugs through. Passenger side went smooth.

Truck sounds great with the new plugs. The old plugs had normal wear, but oddly, were gapped a full 0.01 below spec, like around 0.044. Very strange.

 

[masospaghetti]

Driver's side is a bit annoying but it should not be that difficult. It's easier if you take off one of the sensors on the side of the manifold (2 screws and one connector). Also it's easier if you fish the wire in from the top-down (starting at the coil side), since the coil side plug is larger and more difficult to route through the opening.

 

[TsherryUSA]

Driver's side is a bit annoying but it should not be that difficult. It's easier if you take off one of the sensors on the side of the manifold (2 screws and one connector). Also it's easier if you fish the wire in from the top-down (starting at the coil side), since the coil side plug is larger and more difficult to route through the opening.

Removing the sensor would've been a good idea. Agree with fishing them down from the top, that's what I did. Wiped plug clean once through and added the dialectic grease.

 

[410Fortune]

You guys just use a 10mm and unhook the big 42 pin wiring plug, then a flathead screwdriver to release the female plug from its bracket.
Now you can fish spark plug wires under the intake until your heart is content!

 

[96eb96]

96 has a totally different setup. Wires do not go thru the intake, they go around the back. There is also a heavy steel bracket that the coil pack sits on. Two bolts on the intake manifold, one on the exhaust. It wraps over the passenger valve cover. Definitely a cost saving move there. The upper intake is also a bit different.