Doing a tune-up this weekend and that includes changing plugs and wires. I have the elbows, wobbles and beer to help me through the plug portion. I've also made sure that the little kids in my area will be safely stowed away at parks and shopping malls so that the profanity that is sure to erupt doesn't reach their innocent ears.
My question though is how do you best route the new cables under the intake. It seems like its going to be a pain. Is it one at a time? Do I need a coat hanger to pull them through? Do I need to remove the intake? If so, will there be a gasket issue?
My 96 OHV should be very similar. I don't see any wires under the intake(even in the service manual)! There are wires that go behind. Do not remove any intakes or gaskets. You may need a step ladder to get the wire around the back of the engine. Also, you can fish your new wire by taping it to the old one and gently pulling back. Be sure you remove all the clips before doing this. Use Motorcraft plugs and wires. I don't suggest anything else. You can get them from RockAuto or Autozone locally. Don't cut corners here. Don't forget tune up grease on the boots. Be sure to preserve the original wire order!
Item Part Number Description
1 W703402-S Clip, Quad
2 12287 Spark Plug Wire No. 4
3 12285 Spark Plug Wire No. 6
4 12282 Spark Plug Wire No. 5
5 12286 Spark Plug Wire No. 1
6 12283 Spark Plug Wire No. 2
7 12284 Spark Plug Wire No. 3
8 W700891-S Clip (4 Req'd)
9 E4AE-12297-CA Separator, 4-Way
10 W700891-S Clip
11 E865603-S Clip, Quad (2 Req'd)
CAUTION: Proper installation of spark plug wires is critical to vehicle operation. If one spark plug wire is not properly installed on spark plug or ignition coil, both spark plugs connected to that ignition coil may not fire under load.
Whenever a high tension wire is removed for any reason from a spark plug or ignition coil, or a new spark plug wire is installed, apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19331-AA Motorcraft WAIO, or equivalent meeting Ford specification ESA-M1C171-1C171-A to the boot prior to installation. Using a small, clean tool, coat the entire interior surface of the boot with the compound.
Install each spark plug wire on the proper ignition coil. Refer to the previous illustration which shows spark plug wire routing. The terminal cylinder numbers are identified on the ignition coil. Make sure that the coil wire boots are fully seated and that both coil boot retainer locking tabs have engaged. The 4.0L firing order is 1-4-2-5-3-6.
Remove the wire retaining brackets from the old spark plug wires and install brackets in same relative position on the new wires. Install spark plug wires and retaining brackets on the engine (6007).
Connect spark plug wires to proper spark plugs.