What is best way to replace back 3 spark plugs on a Ford Freestar - Mercury Monterey?

Answer 1

SEE THIS BULLETIN AT Ford.COM TSB 06-5-9

TSB Notes:

• This TSB was superseded 2 times, first with TSB 06-15-2, and the most current, TSB 08-1-9
• Ford.com is terrible place to get TSB information - better off to web search it
• The TSB gives instructions for dealing with a stuck spark plug
• This TSB is NOT relevant to the Freestar / Monterey / Windstar engines

AnswerSince the Freestar / Monterey are the direct spin off of the 2003 Windstar, the information for the same question regarding the Windstar is very applicable. (see below) AnswerThe easiest and fast way to reach the rear plugs is to remove the wiper cowling. Should only take about 10-15 minutes to remove.

Will make the job a whole lot easier!

See "Related Questions" below.

AnswerAfter several hours and searching the net to no avail, kicking back with a beer I realized you must remove the entire plastic cowling and ducting and windshield wiper arms to gain access to the rear bank of spark plugs - easier than performing a feat of gymnastics and contortion to get your arm and wrench into position, especially for #1 cylinder

NOTE: one of the new LONG reach spark plug sockets make the job much easier

ANSWER

I just did this on my 2004 Freestar.10/09. After realizing that underneath was out, I may have found a bit of a short cut. I removed the a/c-heater air intake assy. It's just 2 nuts and a little wiggling and it pops right out. This opens up a large access to the rear of the engine making 2 of the plugs very easy and the third just a little harder. It helps to have a variety of socket wrenches and extensions. I hope this helps someone.

ANSWER

This can be a complicated procedure if you go about it the wrong way. However, it is a very straight forward job which should only take a maximum of two hours tops! All you need is a simple socket set, a flat tip screwdriver and a little patience.

First- Remove the passenger side windshield wiper arm.

Second- Remove the plastic cowling and plastic grommits. There are approximately 10 small mounting bolts. Don't forget the one under the cabin filter. The entire unit should easily come out, including the wiper motor (disconnect wiring harness and two fluid tubes).

Third- Remove a/c duct intake housing.

Fourth-All six plugs can be easily removed with an appropriate spark plug socket, 3/8 or 1/2 drive with a 3-5 inch extension. Be sure to use dielectric grease and anti-seize. Also, ensure all the wires are properly alingned and does not interfere with the exhaust manifold or cooling fan.

Fifth- Repeat steps in reverse. Ensure wiper arm is properly aligned.