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Spark Plug Replacement

upjeff

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July 12, 2007
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City, State
Lakewood, CA
Year, Model & Trim Level
2003 XLS
My 2003 Explorer XLS (6cyl) has 135,000 miles and I never done any major tune up work. I want to change the spark plugs, how difficult is it? Can all the plugs be taken out from the top of the engine compartment or do you have to go through the wheel well?

What other items should I replace? I do the air filter all the time.

Jeff
 



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I'd get a set of wires for it right away too. Definitely get a quality set though...There's a lot of real junk in spark plug wires polluting the shelves of the parts stores. Personally on these engines, I go right to Ford for them. They're priced similarly to the aftermarkets, and you know you're getting a quality replacement. Otherwise, Carquest makes some excellent wires, as does NAPA. I would avoid the ones sold at AutoZone and Advance Auto Parts though. We've had numerous failures with the wires from both places.

Changing plugs on these is simple. Took me about a half hour, and I was taking my time. You need a long (2') extension, swivel joint and 5/8" plug socket to start. You may want a couple shorter extensions too, but I prefer a long one for all but one or two plugs. Just seems to make life easier. You're not busting your knuckles on all the things in the engine compartment this way.
You do them from the top.

Here's a tip: Take a boot from an old spark plug wire, and use it as an installation aid when putting the new plugs in. You can thread them in most the way by hand this way, and only need to give them their final torque with your ratchet and socket. Put a very small dab of anti-sieze compound on the threads of the new plugs before installing.

For plugs, I went with Autolite XP103 Iridium plugs. They weren't much more than the double platinums that are OEM installed, and since they were new, I thought I'd give them a try. Definitely go with Autolite plugs, regardless of which style you buy. Avoid any Bosch spark plug like the plague. Junk, plain and simple.

Might not be a bad time to toss in a new fuel filter too. If the plugs are original, chances are this is too.
 






Thank you for the plug advice

Can you tell me how difficult it is to replace the fuel filter? I have never don eit on the Explorer.

Jeff
2003 XLS
135,000 miles
 






just a quick question...

dont you have to gap the spark plugs? ive heard of people gapping to spec before putting them itno the engine.

also...if changing the spark plugs is this easy then im doing it myself. hopefully there will be a reply on how to change the fuel filter. i feel comfortable doing this maintainence myself and saving MUCHO money...i got a quote on the 60,000 mile service and the stealership wanted $411.14 for it. Is it necessary to get the 60,000 mile service done?
 












just a quick question...

dont you have to gap the spark plugs? ive heard of people gapping to spec before putting them itno the engine.

also...if changing the spark plugs is this easy then im doing it myself. hopefully there will be a reply on how to change the fuel filter. i feel comfortable doing this maintainence myself and saving MUCHO money...i got a quote on the 60,000 mile service and the stealership wanted $411.14 for it. Is it necessary to get the 60,000 mile service done?
If you search this forum, you'll find a few detailed how-to's on changing the fuel filter. It's pretty easy. You'll need a special disconnect tool to remove the lines from the filter, but most auto parts places have them at a reasonable price.

You do have to gap the spark plugs. Ford's specified gap on this engine is 0.054".
The only type of plugs that do not need to be gapped are the multi-electrode style like Bosch Platinum+4 or similar. I would not recommend that this brand or style of plug be used in this engine anyhow, so that's a non-issue.

The only other things that are done at the 60K are mostly just preventive maintenance. Look thru the scheduled maintenance booklet, and you'll see a lot of things listed that are quite simple to do and cost very little.

We're here to help if you have a question on something else in that 60K that you'd be unsure of.
 






dont you have to gap the spark plugs? ive heard of people gapping to spec before putting them itno the engine.

Always check the gap.

also...if changing the spark plugs is this easy then im doing it myself.

Changing the plugs is a pain in the arss. You can definately do it but its a real pain in the arse.
 






Changing the plugs is a pain in the arss. You can definately do it but its a real pain in the arse.
On which engine? The 4.0 SOHC was cake! Like I mentioned, it took me no more than a half hour to do all 6, and I wasn't really rushing.

For the record, Motor's shop time to R&R the spark plugs on the 4.0 is 0.9 hours, and I think they're being a bit generous. That's a job the tech would call a "gravy job" since you can do them far faster than the flat rate book pays.

You want a car that's a PITA to change plugs on? Look at a DOHC or SHO Taurus, or even a late '90s Caravan. Or the worst one I've encountered, a 5.4L F-150 or Expedition. Motor shop time for a tune up on a 5.4L Expy is 3.2 hours! You have to pull the fuel rail up and out of the way to get at the last two on the right bank! Them really suck!
 






On which engine? The 4.0 SOHC was cake! Like I mentioned, it took me no more than a half hour to do all 6, and I wasn't really rushing.

Mine is a 4.0 SOHC and it definately takes longer than 30 minutes. Further, it almost requires going through the fenderwell to get some of them.
 






I believe there's a BIG access difference between the Gen II and Gen III Explorers. Changing the plugs in a '95-'01 X is no picnic. I'm an experienced mechanic, and it took two of us about 4 hours last night to change a set of plugs and wires on a '98 Sport. The driver's side isn't too bad, but the middle plug on the passenger's side is an absolute SOB to get out...especially if the plugs have been in for a long time. That plug took us the better part of an hour by itself.

My '94 isn't too bad to do. I can swap them in under an hour with only a little fuss on the back passenger's side plug.

I hate the thought of having to change the plugs in my '05 F'150 with the 5.4......THAT is going to be a royal PITA!:eek:
 






Mine is a 4.0 SOHC and it definately takes longer than 30 minutes. Further, it almost requires going through the fenderwell to get some of them.

On the driver's side, I just used a long (2 1/2 foot) 3/8" extension and my swivel spark plug socket. That was the easy side. The passenger's side took a little more doing, but with a shorter (6") extension and the same swivel socket, I was able to get to them all from the top.

On a difficulty scale of 1-10, 10 being the hardest, I'd rate this one a 3.
For comparison's sake, a Chrysler 2.2 would be a 1 and a Ford 5.4 an 8 or 9. I'm sure there's some out there that suck even more, so I can't really vote it a 10. Maybe a 1980 Chevy Monza with a 305 would be a 10+. You had to lift the engine up off the mounts to gain access to the spark plugs on those.

BTW, Motor's labor time on the '95-'01 is 1.2 hours.
 












I believe there's a BIG access difference between the Gen II and Gen III Explorers. Changing the plugs in a '95-'01 X is no picnic. I'm an experienced mechanic, and it took two of us about 4 hours last night to change a set of plugs and wires on a '98 Sport. The driver's side isn't too bad, but the middle plug on the passenger's side is an absolute SOB to get out...especially if the plugs have been in for a long time. That plug took us the better part of an hour by itself.

I told my senior mechanic about how long it took you to do plugs on this, and he couldn't remember how long the last one took him, but he'd have known it if it took 4 hours. For that matter, so would I. I would have wanted to know why I was paying 4 hours labor to change 6 spark plugs and a set of wires.
Well, a couple days ago, we got a tune-up job on a '97 Sport, and I got the plugs all laid out and gapped for him, then timed how long it took him to change all 6.
Drum roll please...

18 minutes!

Took about another 35 minutes to do the plug wires, getting them clips all undone and routed back in correctly. Still, well under the labor guide time, which we've determined is extremely generous on these vehicles for tune-up times.
 






Is that an OHV or SOHC motor in the '97? Plugs in the OHV motor aren't too bad...it's definitely worse on the SOHC motor.

The stuff that caused us grief on the '98 SOHC motor was stuck plugs, boots frozen to the plugs, and just lack of space to get to the #2 plug. Several of the plugs were so tight we had to put a breaker bar on them to remove 'em...previous owner didn't use anti sieze on them and certainly must have been a gorilla.....
 






Was that super fast plug job on original plugs? Or on plugs with antiseeze?
 






my 03 4.0 took me about 20 minutes. its a lot easier if you take the cover off the TB and remove the air intake tube.
now my 91 ranger took me a about an hour and half, because of the dual plug 2.3l have to take the alt. and stuff off the driver side to get to the plugs, pass. side was easy, 10 miinutes tops.
 






The '97 Sport had the SOHC engine. Plugs and wires appeared to be original. The truck had ~80K on it, and the (Motorcraft) plugs were definitely shot. There wasn't even any platinum left on the electrodes! The wires were Motorcraft, and had the cylinder numbers on them, so that leads me to believe they were original too.
 






I have an '03 x/xls 4L 6cyl. and I agree with those who say it's easy to change the plugs on this one. I've done it a couple of times. It was harder to change the wires! Like was suggested earlier, just move the air intake tube out of the way and VIOLA.....easy access. It was so easy I replaced the plugs with the Motocraft platinums and tried them and then I tried the Autolite Iridiums. Verdict....AUTOLITE...faster response...better accelleration and crisper shifting. Only took about 30-45 min. to change the plugs.
 






I just finished changing my plugs...about a half hour ago
It was a real PITA, but I'm glad I did it myself
 



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I picked up some plugs the other day at autozone - got the motorcraft ones. So these aren't gapped for my truck and I'll have to gap them?

Also, should I go ahead and pick up the wire set? I have a 2005 with about 72500 miles on it. I think I should be getting the tranny flushed pretty soon, too.
 






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