Frustrating ignition problem.

[Aeroguy]

Solved.

The van ran better for two weeks after finding the wiring problem, but it still had problems when it was cold. Then after that, it started missing all the time. I checked all the wiring and there were no further connection problems.

About two years ago, I brought the Aerostar in for a diagnostic for pretty much the same problem. What they ended up doing was replacing four of the spark plugs before they found a bad spark plug wire (brand new wire that had a slash in the boot). I replaced the wires and hadn't had any problems until last January. When this problem first started, I checked the wires again, but everything was good. The other day, while brainstorming what else I could test, I happened to look at the bill for the 'diagnostic' service... the bill claimed they installed four Motorcraft SP486 spark plugs. That didn't sound familiar, so I checked which plugs I had installed and they were Motorcraft SP500. I checked three different websites and all said the SP500 were the correct plugs. So I was running on two SP500s and four SP486s.I bought a new set of plugs, installed them and surprise! No more problems! Not sure what the difference is between the SP486 and SP500, but the problem is entirely gone and the van is running perfectly.

Thanks for the help!

 

[robcarz]

Bravo this may save someone else a lot of trouble.

 

[BrooklynBay]

Thanks for the update!

 

[speleopower]

Wow what a detective story. Good work!
I'm having a similar issue with my van regarding a slight rough idle and running just after turning the van on in the morning. The problem goes away after a minute or so. I'm about to replace the plugs, wires and the coil pack block. I replaced all of these about 4 years ago and everything was working great until I severly overheated a couple months ago. I've been having issues ever since.

Scott

 

[Malk67]

OK, been reading through this thread. Seems to be some of my current issues as well. I replaced the fuel pressure regulator just the other day in hopes that may have been part of my "strong gas smell" when running. I'm gonna change out my plugs again to DbP, am currently running Bosch Plats. I just replaced the rear cat. and now It would seem that BOTH are now shot. Cat's got so hot they "cooked" the flex pipe behind the rear one. At one point even the muffler (which is only about 1 1/2 YO) was Also red hot.
Also the coil pack is less than a month old. If I didn't already shave my head I would have pulled my hair out completely.
What really puzzles me is that they will heat up, turn red, and then a bit later while driving will "cool down" loosing the "red hot" look.
I know I need to service the tranny, am getting some slippage at various speeds and really bad when she's cold. I plan on dumping the fluid and replacing the filter, running her for awhile then getting a "tranny flush".
Again, I'm at a loss as to what exactly my fuel issue is. I've also recently used some fuel system cleaner and on a sepperate fill up added some Iso HEET. Every additive I've used say's they're "Cat Safe" but I'm a lil leary that added the Iso may have caused the fuel to burn a little TOO hot.

 

[BrooklynBay]

Your catalytic converter sounds like it's clogged. Heat is building up inside from the hot exhaust, and has nowhere to escape. It's not supposed to turn red.

 

[Malk67]

UPDATE
Changed out the wires and 5 plugs w/Autolite Double Plat's (trying to find an easy way to change #6).
Running smooth, instant startup, no "raw gas" smell. The cat's are staying cool, just need to replace the flex pipe.

 

[BrooklynBay]

Thanks for the update!