Lincoln

Ford F150, Mustang, 3-Valve 5.4 / 4.6 VCT Solenoid Failure, Trouble Codes P0022 or P0012, Variable Camshaft Timing. Can cause lost power, check engine light, poor fuel mileage.

- Basic System Overview and Operation

The Ford 4.6 Liter 3-Valve motor is the first modular Ford V8 to incorporate variable camshaft timing (VCT). Variable valve timing adjusts the angle of the camshaft while the engine is running to increase horsepower, and fuel economy. This system is controlled by the engine computer, which operates a solenoid on the top of each cylinder head inside the valve cover. This solenoid allows pressurized oil to flow to the camshaft sprocket, which on this system, Ford calls a “Cam Phaser.” The cam phaser becomes pressurized by engine oil and changes the camshaft timing by varying the offset of the camshaft gear. (See our post http://www.autopartsdirecttoyou.info/?p=70 for more information on the cam phaser).

- VCT Solenoid Failure

VCT Solenoid

You can click here to find the Original Equipment Ford VCT Solenoid

The VCT (Variable Cam Timing) solenoid is one point of potential failure in this system. The solenoid is exposed to harsh conditions inside the valve cover. Excessive heat, and lack of engine oil changes are two of the most damaging factors that can kill the VCT Solenoid. When the engine computer recognizes that the VCT solenoid is not operating properly, it can trigger any of the trouble codes listed below. Failure of a VCT solenoid can also cause poor engine performance, rough running, and decreased fuel economy.

- Trouble Codes indicating possible VCT Solenoid Failure

** Please note, these codes can all be indications of other problems in the VCT system, such as the camshaft phaser or wiring.

P0010 : Intake Camshaft Position Actuator Circuit Open, Bank 1 (Passenger Side)
P0011 : Intake Camshaft Position Timing Over-Advanced, Bank 1 (Passenger Side)
P0012 : Intake Camshaft Position FTiming – Over-Retarded, Bank 1 (Passenger Side)
P0020 : Intake Camshaft Position Actuator Circuit Open, Bank 2 (Driver Side)
P0021 : Intake Camshaft Position Timing – Over Advanced, Bank 2 (Driver Side)
P0022 : Intake Camshaft Position Timing – Over-Retarded, Bank 2 (Driver Side)

** Please note, these codes can all be indications of other problems in the VCT system, such as the camshaft phaser or wiring.

 

Drivers Side VCT Solenoid. Passenger side is similar.

VCT Solenoid Location

VCT Solenoid


Reprogramming procedure for Mercury, Ford and Lincoln Keyless Entry Transmitters or more commonly know as a Key Fob.

Most modern vehicles come with the option for keyless entry. The problem is that these transmitters drop, break, get lost, rubber buttons wear, contacts inside become corroded and the plastic case can crack. TechSmart™ offers one of the most common keyless entry transmitters providing a high-quality, cost effective solution to replace the damaged or lost original.

Some helpful hints on reprogramming your keyless entry transmitter (key fob)

Electonically unlock all doors prior to attempting to enter Remote entry programming mode. Do not press the brake pedal during manual remote entry programming procedure as it will immediately exit you from that mode  (this is to protect against confusion with TPMS learn mode.) If only one transmitter needs to be added or replaced, this can be accomplished via the diagnostic programming procedure using a service scan tool, instead of erasing all transmitters from memory using the manual key cycle method. Keep in mind, most systems only allow 4 devices to be programmed to the vehicle. For example, if a vehicle capable of accepting 4 transmitter devices and is fitted with a wireless keypad, then it can only accept three other transmitters (key fob) devices.

Typical Transmitter programming using the manual key cycle method.

2011-2006 Ford Crown Victoria
2011-2006 Mercury Grand Marquis

Open drivers window. Turn ignition switch from LOCK to RUN position 4 times within 3 seconds ending in RUN position. Door locks will lock then unlock to verify programming mode has been entered. Press any button on transmitter to be programmed. Within 7.5 seconds, press any button on next transmitter to be programmed and so on untill all transmitters are programmed. To exit programming mode, turn ignition switch to START position or wait for more than 7.5 seconds.

2003-1998 Ford Escort
1999-1998 Mercury Tracer

To reprogram all transmitters, cycle ignition switch from LOCK to RUN postion 8 times within 10 seconds, ending in RUN position or LOCK to START position 4 times in 10 seconds, ending in RUN position. After doors lock and unlock, press any button on all remotes transmitters (up to limit of 4). With each button pressed on remote transmitter, door locks should cycle (lock/unlock) to confirm programming. Once completed, turn ignition switch to LOCK postion. Door lock should cycle (lock/unlock) one last time to comfirm completion of programming. All transmitters must be reprogrammed at the same time.

2011-1999 Ford Mustang
2006-2005 Ford GT
2010-1998 Ford Light Truck Expedition
2010-1998 Lincoln Navigator

Open driver’s window. Cycle ignition key from LOCK to RUN 8 times within 10 seconds ending in RUN postion. Doors will lock, then unlock to verify program mode has been entered. Within 7.5 seconds, press any button on transmitter. Doors will lock, then unlock to confirm transmitter has been programmed. Turn ignition switch to LOCK postion or wait 5 minutes to exit program mode. Doors will lock, then unlock to confirm program mode has been exited.

2007-1998 Ford Taurus
2005-1998 Mercury Sable

1. Ensure anti-theft system is not armed. Turn ignition switch from LOCK to RUN position 8 times within 10 seconds ending in RUN position. The system will indicate entry into programed mode by locking and unlocking all doors.
2. Press any button on remote transmitter within 20 seconds. Doors will lock and unlock to confirm transmitter has been programmed. Repeat procedure to program additional transmitters.
3. Turn ignition switch to LOCK position to exit program mode. If a new set of transmitters have been programmed, RAP module will lock and unlock all doors one last time to confirm programming was successful. If system does not program successfully, repeat procedure. If system will not program, repair remote keyless entry system as necessary.

2010-1998 Ford Light Truck Explorer / Sport / Sport Trac
2010-1998 Mercury Mountaineer
2005-2003 Lincoln Aviator

Open driver’s window. Cycle ignition key from LOCK to RUN 5 times within 10 seconds ending in RUN position. Doors will lock, then unlock to verify program mode has been entered. Press any button on transmitter. Doors will lock, then unlock to confirm transmitter has been programmed. Turn ignition switch to LOCK position or wait 20 seconds to exit program mode. Doors will lock, then unlock to confirm program mode has been exited.

2011-2004 Lincoln Town Car
1. Cycle ignition switch from LOCK to RUN positions 4 times within 3 seconds. Locks will lock and unlock to confirm programming mode has been entered. Press any button on remote transmitter.
2. If additional remote transmitters are to be programmed, press any button on remaining remote transmitters within 7.5 seconds. To exit programming mode, turn ignition switch to START position or wait 7.5 seconds.
3. To set a remote transmitter to also operate a memory set postion, press SET button on memory switch then press any button on remote transmitter then appropriate memory button (1 or 2). To unassociate a transmitter, repeat this step.

1998-2003 Lincoln Town Car
Turn the ignition from OFF to RUN 4 times within 3 seconds, with the 4th time ending in RUN. All doors will lock then unlock to confirm programming mode. Within 20 seconds, press any button on the 1st remote transmitter. Door locks will cycle to confirm programming. Within 20 seconds, press any button on the 2nd transmitter (up to 4 transmitters total possible). Turn the ignition OFF. Locks will again cycle to indicate end of programming mode.

2002-1999 Mercury Cougar
1. Open driver’s window. Turn ignition switch to RUN or ACC position. Access programming connector. Programming connector is behind left trunk trim panel, attached to relay panel. Using jumper wire, momentarily short the 2 terminals of programming connector together. Both doors should lock then unlock to confirm program mode has been entered.
2. Press any button on keyless entry remote transmitter. Both doors should lock thae unlock to confirm that transmitter has been programmed.
3. Repeat step 2, to program all other transmitters (maximun of 4 transmitters) to be used with this system before exiting programming, turn iginition switch to LOCK position. To confirm programming mode has been exited, both doors should lock then unlock.

2007-2005 Ford Five Hundred
2007-2005 Mercury Montego
2005-2002 Ford Thunderbird
2006-2000 Lincoln LS

Do not press the brake pedal during manual remote entry programming procedure as it will immediately exit you from that mode. Electronically unlock the vehicle prior to attempting to enter Remote Entry Programming Mode. Turn ignition from OFF to RUN 8 times within 10 seconds, with the 8th time ending in RUN. All doors will lock then unlock to confirm programming mode. Within 20 seconds, press any button on 1st remote reansmitter. Door locks will cycle to confirm programming. Within 20 seconds, press any button on the 2nd transmitter (up to 4 transmitters total possible). Turn ignition to OFF. Locks will again cycle to indicate end of programming mode.

2011-2000 Ford Focus
Turn the ignition from OFF to RUN 4 times within 6 seconds. Turn the ignition OFF. The system will chime to comfirm programming mode has been entered. Within 20 seconds, press any button on 1st transmitter. The system chime once to confirm programming. Within 20 seconds, press any button on 2nd transmitter (up to 4 transmitters total possible). Turn the ignition to RUN to exit programming mode.


What is a Electronic Throttle Body or commonly referred to as Throttle-By-Wire, Fly-By-Wire, Drive-By-Wire (DBW) or Throttle Actuator Control (TAC)?

Electronic Throttle Bodies? Where’s the throttle cable? As you may already know opening the hood in a modern car reveals systems alot different than that of years past. As engine life has been extended and engine controls have become more complex, longer-life and higher-reliability electronic components are required. These advances in electronic componets aid the Power Control Module (PCM) to stay within the programed perimeters for the best performance and emission regulations.  One of these components being the Electronic Throttle Control (ETC) system often referred to as throttle-by-wire, fly-by-wire, drive-by-wire (DBW) or throttle actuator control (TAC). Using a array of sensors the on-board computer system measures throttle demand, then sends out a signal (electronic command) to the electronic throttle body. This computer command is to operate a servo motor controlling the throttle plate/blade or butterfly.

What seems to be the failure of the Electronic Throttle Body is the plastic gear drive. A common problem of the throttle body bore has been a build up of gases from the EGR and PVC systems, combined with heat causes a formation of gummy residue. This gummy residue often restricts airflow causing poor or hunting idle and even stalling conditions. This residue can become so built up that it causes the throttle body plate/blade to stick, striping out the gear drive in the throttle body.

TechSmart™ has a complete line of New Electronic Throttle Bodies, offering a cost effective solution for repairing  failed electronic throttle bodies for many makes and models.

S20001
2010-2009 Ford Light Truck Expedition
2010-2009 Ford Light Truck F Series Fullsize Pickup
2010-2009 Lincoln Navigator

S20002
2007-2006 Cadillac CTS
2008-2006 Chevrolet Corvette
2009-2008 Pontiac G8
2006-2005 Pontiac GTO

S20003
2007-2006 Buick Rendezvous
2006-2005 Buick Terraza
2006-2005 Chevrolet Malibu / Malibu Maxx
2006-2005 Chevrolet Light Truck Equinox
2006-2005 Chevrolet Light Truck Uplander
2006-2005 Pontiac G6
2006-2005 Pontiac Montana
2006-2005 Saturn Relay

S20004
2008-2006 Buick LaCrosse
2006 Buick Rendezvous
2007-2006 Cadillac CTS
2006 Cadillac SRX
2007-2006 Cadillac STS

S20005
2006-2004 Cadillac SRX
2009-2006 Cadillac XLR
2006-2005 Pontiac Torrent

S20006
2004 Buick Rainier,
2006-2003 Cadillac Escalade,
2006-2003 Chevrolet Light Truck Fullsize Pickup
2007-2004 Chevrolet Light Truck G Series Fullsize Van / Express
2006-2003 Chevrolet Light Truck Suburban / Fullsize Blazer / Tahoe
2004-2003 Chevrolet Light Truck Trailblazer
2004-2003 GMC Light Truck Envoy,
2006-2003 GMC Light Truck Fullsize Pickup
2007-2004 GMC Light Truck G Series Fullsize Van / Savana
2006-2003 GMC Light Truck Suburban / Fullsize Jimmy / Yukon
2007-2005 Hummer H2

S20007
2004-2003 Oldsmobile Bravada
2007 Chevrolet Light Truck Colorado
2007 GMC Light Truck Canyon
2007 Hummer H3
2007-2003 Buick Rainier
2007-2003 Chevrolet Light Truck Trailblazer
2007-2003 GMC Light Truck Envoy
07-05 Pontiac Grand Prix
2007-2005 Saab 9-7
2007-2006 Chevrolet Impala

S20009
2007 Saturn Aura
2009 Saturn Vue
2009,2010 Buick Lucerne
2009,2010 Chevrolet Impala
2009-2006 Chevrolet Light Truck Uplander
2009-2006 Pontiac Montana
2009-2006,2010 Chevrolet Malibu / Malibu Maxx
2009-2006,2010 Pontiac G6
2009-2007 Chevrolet Light Truck Equinox
2009-2007 Pontiac Torrent

S20010
2001-1999 Cadillac Catera
2004-2003 Cadillac CTS

S20011
2002 Chevrolet Light Truck Trailblazer
2002 GMC Light Truck Envoy
2002 Oldsmobile Bravada

S20012
2008-2005 Pontiac Grand Prix
2008-2006 Buick Lucerne
2009-2005 Buick LaCrosse

S20013
2007 Chevrolet Light Truck Colorado
2007 GMC Light Truck Canyon
2007-2004 Saturn Ion
2007-2005 Chevrolet Cobalt

S20014
2006-2003 Chevrolet Light Truck Suburban / Fullsize Blazer / Tahoe
2006-2003 GMC Light Truck Suburban / Fullsize Jimmy / Yukon
2007-2003 Chevrolet Light Truck Fullsize Pickup
2007-2003 GMC Light Truck Fullsize Pickup

S20015
2009-2008,2010 Chevrolet Light Truck HHR
2009-2008,2010 Chevrolet Malibu / Malibu Maxx
2010 Chevrolet Light Truck Equinox
2010 GMC Light Truck Terrain

S20016
2008-2007 Chevrolet Malibu / Malibu Maxx
2009-2007 Pontiac G5
2009-2007,2010 Chevrolet Cobalt
2009-2007,2010 Chevrolet Light Truck HHR

S20017
2009-2007 Saturn Outlook
2009-2007 Saturn Vue
2009-2007 Suzuki XL-7
2009-2007,2010 GMC Light Truck Acadia
2009-2008 Chevrolet Light Truck Equinox
2009-2008 Pontiac Torrent
2009-2008,2010 Buick Enclave
2010 Buick LaCrosse

S20018
2009-2007,2010 Cadillac SRX
2009-2008,2010 Cadillac CTS
2009-2008,2010 Cadillac STS
2010 Buick LaCrosse
2010 Chevrolet Camaro
2010 Chevrolet Light Truck Equinox
2010 GMC Light Truck Terrain

S20019
2009 Chevrolet Light Truck Avalanche
2009 Chevrolet Light Truck Suburban / Fullsize Blazer / Tahoe
2009 GMC Light Truck G Series Fullsize Van / Savana
2009 GMC Light Truck Suburban / Fullsize Jimmy / Yukon
2009 Hummer H2
2009-2010 Cadillac Escalade
2009-2010 Chevrolet Corvette
2009-2010 Chevrolet Light Truck Colorado
2009-2010 Chevrolet Light Truck Fullsize Pickup
2009-2010 Chevrolet Light Truck G Series Fullsize Van / Express
2009-2010 GMC Light Truck Canyon
2009-2010 GMC Light Truck Fullsize Pickup

S20020
2009-2010 Ford Crown Victoria
2009-2010 Ford Light Truck E Series Fullsize Van
2009-2010 Ford Mustang
2009-2010 Lincoln Town Car
2009-2010 Mercury Grand Marquis

S20021
2009-2010 Ford Light Truck E Series Fullsize Van
2009-2008 Ford Mustang

S20022
2008-2006 Ford Light Truck Explorer / Sport / Sport Trac
2008-2006 Mercury Mountaineer

S20023
2005-2004 Ford Light Truck Explorer / Sport / Sport Trac
2005-2004 Mercury Mountaineer

S20024
2006-2003 Chevrolet Light Truck G Series Fullsize Van / Express
2006-2003 GMC Light Truck G Series Fullsize Van / Savana

S20025
2007-2005 Ford Five Hundred,
2007-2005 Ford Light Truck Freestyle
2007-2005 Mercury Montego

S20026
2009-2006 Ford Fusion
2009-2006 Mercury Milan

S20027
2010 Ford Light Truck Transit Connect

S20028
2006 Lincoln Zephyr
2009-2006 Ford Fusion
2009-2006 Mercury Milan

S20030
2002-2001 Chevrolet Light Truck Fullsize Pickup
2002-2001 Chevrolet Light Truck G Series Fullsize Van / Express
2002-2001 GMC Light Truck Fullsize Pickup
2002-2001 GMC Light Truck G Series Fullsize Van / Savana
1999-1998 Chevrolet Light Truck P Series Van
1999-1998 GMCLight Truck P Series Van

S20031
2004-2000 Chevrolet Corvette
2005-2004 Cadillac CTS

S20032
2002 Cadillac Escalade
2002 Chevrolet Light Truck Avalanche
2002-2000 Chevrolet Light Truck Fullsize Pickup
2002-2000 GMC Light Truck Fullsize Pickup

S20034
2008-2005 Pontiac Vibe

S20035
2004 Pontiac Grand Prix

S20036
2002-1999 Chevrolet Camaro
2002-1999 Pontiac Firebird

S20038
2009-2005,2010 Ford Mustang


Ford Vechicles with repeated false EGR codes, due to Delta Pressure Feedback of EGR (DPFE) Hose having vacuum leak

Ford vehicles with Pressure Feedback EGR Sensors (PFE) or Differential Pressure Feedback EGR Sensor (DPFE), may experience repeated false codes for the EGR system. This condition may be due to a hose problem, this hose is subject to high temperatures (melting) and carbon debris blockage.

Other than a repeated check engine light, some driveability conditions that may be experienced include engine bucking (surging) during initial off-idle acceleration or cruising and may become as bad as engine stalling during deceleration.

This TechSmart™ kit is a real problem solver featuring an extra heavy-duty hi-temp design to handle the pressure that ordinary hoses cannot.

DPFE hose kit M40001

Delta Pressure Feedback of EGR (DPFE)  part # M40001

2000-1995 Lincoln Town Car
2000-1998 Ford Contour
2000-1998 Mercury Grand Marquis
2000-1998 Mercury Mystique�
2000-1999, 1995-1994 Mercury Cougar
2001-1996 Ford Light Truck Explorer / Sport / Sport Trac
2001-1997 Ford Light Truck Windstar
2001-1997 Mercury Mountaineer
2002 Ford Thunderbird
2002 Lincoln Blackwood�
2002-2000 Lincoln Ls
2002-1997 Ford Escort�
2002-1998, 1995 Ford Crown Victoria
2002-1999 Lincoln Continental
2004-2003 Ford Light Truck E Series Medium Duty Van
2004-2003 Mazda Tribute
2004-2003, 2000 Ford Focus�
2004-1996 Ford Light Truck E Series Fullsize Van
2004-1996 Ford Light Truck F Series Fullsize Pickup
2004-1997 Ford Light Truck Expedition
2004-98 Lincoln Navigator�
2004-1998, 1995-1994 Ford Mustang�
2005 Lincoln Aviator�
2005-2000 Ford Light Truck Excursion
2005-2003, 2000-1998 Mercury Sable
2007-2003, 2000-1996 Ford Taurus
2007-2005 Mercury Mariner
2007-1998 Ford Light Truck Ranger
2007-1998 Mazda Pickup�
2008-2003 Ford Light Truck Escape
1994 Mercury Capri�
1996 Ford Light Truck Bronco
1999-1998 Mercury Tracer


How To Remove/Replace/Inspect/Install A Camshaft Phaser Sprocket On A Ford/Lincoln Navigator/Mercury Mountaineer For Engine Variable Valve Timing

NOTE: This repair requires extensive knowledge & experience and is probably best done by a professional  ASE certified automotive technician.

The variable valve timing (VVT) camshaft phaser is a sprocket that will alter its position in reference to commands from the PCM for variable valve timing. When this fails, the check engine light is illuminated, the vehicle may run rough, and experience a loss of power along with valve train noise.

Variable valve timing (VVT) Camshaft Phaser Sprocket

TechSmart™ Variable Valve Timing Cam Phaser  part #  S21001 

This repair should be done by a qualified technician and requires a labor time of, left side or both estimated at 10.2 hrs
Special tools required- Valve Spring Compressor OTC 303-1039 and Timing Chain Wedge OTC 303-1175

Timing chain procedures must be followed exactly or damage to valves and piston will result.
CAUTION- damage to the Phaser sprocket will occur if mishandled or used as a lifting or leveraging device.

1. Position the crankshaft pulley spoke to the 12 o’clock position and the timing mark indentation to the 1 o’clock position.

2. Remove the valve cover

3. Loosen and back-off the camshaft phaser, sprocket bolt one full turn

4. Disconnect the camshaft position sensor electrical connector, remove the hold down bolt and sensor.

note- if the camshaft lobes are note exactly positioned as shown, the crankshaft will require one full additional rotation.

Top dead center w/ lobe identifying

Right hand camshaft—-the No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.

Left hand camshaft— the No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder
5. Remove only the 3 camshaft roller followers shown in the illustration.
Caution- Do not allow the valve keepers to fall off the valve or they may drop into the cylinder. Roller Followers must be installed in their original locations. It may be necessary to push the valve down while compressing the spring.

Camshaft followers rollers and tool

After removing the three cam roller followers, rotate the crankshaft clockwise, positioning the crankshaft damper spoke to the 6 o’clock position and the timing mark indentation to the 7 o’clock position.

Crankshaft position just before removing VVT sprocket

Timing chain wedge tool
This tools must be installed square to the timing chain and the engine block. Do not remove tool at any time during servicing, if tool is removed during assembly the engine front cover must be removed to retime engine chain.

Wegde tool, scribe mark and deformed VVT

6. Scribe marks on camshaft phaser and chain, before removing camshaft.

7. Loosen camshaft bearing cap bolts in sequence. Inspect front thrust bearing cap oil metering groove for foreign debris.

bearing cap sequence

If Removing the camshaft do not allow the roller followers to move out of position. All parts removed, bearing caps and rollers need to go back in there original locations.

8. Remove the camshaft phaser.  After removing camshaft phaser sprocket, inspect the sprocket for missing or damaged roll pins.
remove the sprocket from camshaft, is the location pin deformed or damaged,  Replace.

Inspecting the Camshaft Phaser, visually inspect the camshaft phaser and sprocket for squareness. If the trigger wheel or spring is deformed or damaged, install a new camshaft phaser

Camshasft phaser identifying

When installing the new Camshaft Phaser transfer the original scribe mark to the new camshaft phaser sprocket.

9.Install the camshaft into the camshaft phaser sprocket, lining up the dowel pin and installing the sprocket bolt finger-tight

10. Install the camshaft phaser into position, verify the sprocket and timing chain scribe marks are still in alignment.

11.Lubricate and install the camshaft bearing caps. install the front position cap first, then the remaining caps, installing the bolts loosely.

12. Torque camshaft cap bolts in sequence to 89 Lb-in

13. remove the timing cam wedge tool. Rotate the crankshaft counterclockwise half turn, positioning the crankshaft damper spoke at 12 o’clock and the timing mark indentation at 1 o’clock.

verify correct camshaft position-
-Left-hand camshaft position of No. 5 cylinder intake and exhaust lobes
-Right-hand camshaft position of the No. 1 cylinder intake and exhaust camshaft lobes

14.Using the spring compressing  tool, install the 3 originally removed camshaft roller followers

15. Install the CMP sensor and torque bolt to 89 Lb-in. Connect the CMP electrical connector.

16. Use a two step torque sequence, on the Camshaft Phaser Sprocket Bolt
1. tighten to 30 lb-ft
2. tighten an additional 90 degrees
Replaces Ford part #: 3R2Z-6A257-DA
Application(s):

  • Ford Expedition 2005-2011 5.4L V8 24V
  • Ford Explorer 2006-2011 4.6L V8 24V
  • Ford Explorer Sport Trac 2007-2010 4.6L V8 24V
  • Ford F150 2004-2011 5.4L V8 24V
  • Ford F150 2009-2011 4.6L V8 24V
  • Ford F250 Super Duty 2005-2010 5.4L V8 24V
  • Ford F350 Super Duty 2005-2010 5.4L V8 24V
  • Ford F450 Super Duty 2005-2010 5.4L V8 24V
  • Ford F550 Super Duty 2005-2010 5.4L V8 24V
  • Ford Mustang 2005-2010 4.6L V8 24V
  • Lincoln Navigator 2005-2011 5.4L V8 24V
  • Mercury Mountaineer 2006-2011 4.6L V8 24V


Ford Triton V8 Spark Plug Information & How To Repair, Problems Include: Blow Out, Spit Out, Seized, Frozen, Stripped, Broken, Stuck In Cylinder Head, & Special Tools, Thread Inserts Needed To Repair

SKILL LEVEL: Above Average – This repair requires a strong knowledge & experience level of auto repair and may be best done by an ASE certified auto technician.

If you own a Ford Truck made before 2007 and you ever got a very high quote to simply replace spark plugs, then this article is for you. Any shop worth its salt knows full well the issues with trying to remove spark plugs form the Triton V8 3-Valve engine and they will quote it accordingly. They also know that if you attempt to do this job yourself, you will most likely be back to their shop for a much more expensive job of removing or repairing the cylinder heads. The simple fact is that almost every time you attempt to remove these spark plugs, at least one of them breaks off into the cylinder head or worse the threads from the cylinder head are damaged or come out with the spark plug. This article explains the extremely common spark plug problems on Ford V8 engines. Their are 2 different issues to address: The first is one or more spark plug(s) broken off or stuck in the cylinder head, The 2nd is the spark plug has blown out of the cylinder head and/or the threads are stripped or pulled out.

The image below shows a spark plug(in the red circle) broken off inside the cylinder head

Broken spark plug in a Ford F150 Triton V8

Issue #1: Spark plug(s) stuck in cylinder head or broken off.

The OE extended spark plugs on these trucks are very long and the threads are not attached to the body of the spark plug which allows the spark plug to twist from the torque of trying to unscrew it from the cylinder head. This issue normally pops up when spark plugs are being removed & replaced for normal maintenance or misfire problem. Ford’s recommended replacement interval for spark plugs on most all of these affected vehicles is 100,000 miles. My own personal opinion is that waiting until 100,000 miles is asking for trouble and I believe waiting that long contributes to these spark plug problems. A spark plug goes through trillions & trillions of cycles during a 30,000 mile period, imagine how much abuse they go through in 100,000 miles. We see most trucks coming in with a misfire problem at around 60,000-90,000 miles. Also the cylinder head is aluminum, the spark plug has steel and other components and the 2 dissimilar metals will lead to corrosion. Every time I remove spark plugs from one of these Ford engines, the threads of the spark plugs are rusty & the base of the spark plug is rusty. The other thing that leads to these breaking off is that the OE spark plug is a 2 piece design and you can see from the images below the difference. This 2-piece design and waiting to 100,000 miles allows excessive carbon deposits to buildup between the lower electrode of the plug & the upper body of the plug.

motorcraft spark plug vs champion solid one piece design

Champion makes a spark plug that is 1 piece and while you should always try to put OE back on, In this case you may want to consider switching to Champion for their 1 piece design. So with all of that said, If you change your plugs at 30K intervals, you have a much better chance of avoiding the plugs breaking and you may even prolong the life of your ignition coils too.

Recommended steps to try and remove plugs without breaking them:

1. CHANGE THEM EARLY, Do not wait until 100K or until you have a misfire. I do a full tune up on my own truck at 30,000 miles. Of course I enjoy doing this type of work and don’t mind at all.

2. Let the vehicle cool, Ford specifically calls out in their TSB to allow the engine to fully cool and do not attempt spark plug removal on a hot engine. Soak all the spark plugs with a good carb/throttle body cleaner, the goal is for the carbon cleaner to weaken the carbon buildup that naturally occurs on the spark plugs, Spray all around the base of the spark plug and then let is sit for about an hour or more, Repeat as necessary, You can do this the night before and then again the morning of just to help get as much penetration as possible. A high quality penetrating oil should be used next like Aerokroil or PB-Blaster

3. Attempt to loosen each plug very carefully only about 1/4 turn. Use premium good quality tools that allow you to get a good solid strong and square position on each spark plug. Once you have them each 1/4 turn loose, then spray more penetrating oil and let it sit, This may sound like a pain, but if you can get the plugs out without them breaking, you have avoided some serious frustration and cost. The passenger side of the engine is where most breakage occurs so pay special attention their.

4. If a spark plug breaks and it usually will if you wait until 100K, then you will need one of these kits to remove the rest of it from the cylinder head. I have used the Lisle 65600 and it worked like a charm and it only took about 15 minutes. Dorman 42045 is similar, however I have not yet used that one and cannot say how it works but lots of them sell.

Issue #2. Spark plugs are loose or actually blow right out of the cylinder head and typically strip or pull the threads out with them.

Believe it or not this actually happens and it happens very often. Typical symptoms include very loud exhaust popping noise coming from the engine bay area, immediate misfire, and very likely a check engine light will follow shortly their after. Oh and one more symptom is that their is probably a spark plug or pieces of a spark plug laying around in your engine bay somewhere and your ignition coil may or may not still be attached to the top of that spark plug. Look at the coil tower next to the missing spark plug and the retaining bolt and a small piece of the ignition coil are probably still their. Ford has issued a TSB (Technical Service Bulletin) #: 07-21-2 which replaces TSB #: 7-15-2, This TSB explains that Ford has an authorized repair kit available so you can repair the stripped or missing threads inside the cylinder head instead of replacing the cylinder head. Below we have listed the expensive Ford authorized kit & the much cheaper aftermarket ones available.

Tools Needed:

Ford Authorized Repair Kit: Rotunda 302-00001 – Very Expensive

Aftermarket Repair Kits Available:

TimeSert 5553 – Professional Kit

NOT FINISHED, MORE TO COME


Coil Spring Conversion Instructions: Grand Marquis, Town Car, Crown Victoria

Coil Spring Conversion Installation Instructions

Mercury Grand Marquis:  1992 – 2007

Ford Crown Victoria:  1992 – 2007

Lincoln Town Car:  1990 – 2005

Caution! : Working with coil springs can be dangerous. Read and understand these instructions completely before beginning work on the vehicle. Removing original air bags:

1)      Turn off Air suspension switch inside the trunk of the vehicle.

2)      Jack up vehicle and support the FRAME of the vehicle on jack stands. The rear axle assembly MUST be completely unloaded (in other words, hanging freely).

3)      Remove rear wheels

4)      Remove air spring solenoid retaining clip, it is a C shaped metal clip that easily pops off with a small screwdriver.

5)      Rotate the solenoid counterclockwise to its first stop. Pull outward on the solenoid to release the air pressure in the bag. Once the air pressure is fully released, rotate counterclockwise again and pull out, the solenoid will now come out of the air spring.

6)      Remove the large metal clip on top of the air-spring. This clip holds the top of the air-spring to the chassis. A pair of pliers or a large hook shaped tool may be required to remove the Spring-Clip.

7)      Release the lower air-spring seat by prying up on the air spring. The metal clip inside will release from the rear differential housing.

8 )    Unplug the electrical connector on the air-spring solenoid. Remove air line from air-spring solenoid by pushing down on the orange quick-release ring and pull out on the air line at the same time.

Installing New Coil Springs:

1)      With old air springs completely removed. Remove the lower shock mounting bolts. The axle assembly will now hang freely. Install the rubber coil spring isolators on the springs-seats and place the coil springs onto the isolators.

2)      Use a floor jack placed under the center of the differential housing (pumpkin) and slowly jack up the rear axle until the holes for the lower shock bolts are lined up with the shock.

3)      Install the lower shock bolts and tighten to 70ft/lbs. Lower the jack under the rear differential.

4)      Reinstall the wheel assemblies and lower the vehicle to the ground. Torque the rear wheels to 100ft/lbs.

5)      Disconnect  the air suspension computer. On some models it is located behind the trunk carpet. On others it is located behind the glove-box lid.


4.6L Ford, Lincoln, Mercury

Ford Lincoln Mercury 4.6L Intake Manifold Replacement Part 1 Video

 

Ford Lincoln Mercury 4.6L Intake Manifold Replacement Part 2 Video

 

APDTY.com Intake Manifold parts link

Torque Specifications
Intake Manifold Bolts____________15-22 Ft. Lbs.
Thermostat Housing Bolt__________18 Ft. Lbs.
Ignition Coil Bolt_______________53 Inch Lbs.
Fuel Rail Bolt___________________89 Inch Lbs.
Throttle Body Bolt_______________72-106 Inch Lbs.
EGR Valve-To-Intake Manifold_____15-22 Ft Lbs.

 


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