passenger side plugs- through the passenger side wheel well
driver side plugs- under the hood
you have to open the dog house inside of the car right in front of the floor shifter.but don't forget to have the hood up as to let in some more light. and i strongly suggest bosch platnium plugs as they are already gapped and last longer than the cheapies which need changed more often.ie this is not a fun repair on these vans cause there is to little space for all the stuff in there.
A: Of all the vans manufactured, there is no other that will make more techs go into hiding than a Ford Aerostar. Tight working conditions is an understatement for this vehicle. To gain entry to the distributor for service you must remove an access panel on the inside on the van. One or two of the spark plugs may be accessible from this point; the rest are through the wheel wells and from the front of the engine depending on which engine configuration your van is equipped with.
Patience or a good check book balance is the solution to your accessibility dilemma.
he rear spark plugs can be removed and installed by reaching over the top of the engine and using a 1 in extinsion, again it is hard so you have to take your time.
jacked up the front end, took off the tires, and began to take out the passenger side plugs first. I also took off the engine cover to access the back.
My passenger side was okay with typical tools. I replaced the plugs.
The drivers side is a bitch!, but, doable.
The plug closest to the driver is the worst. The engineer(s) who had their hand in this design were either drunk or on something.
Good luck and be patient and replace with antifreeze on the plugs. I did, but I really don't intend on doing this again. I did break one plug ubber cap because I got ticked and twisted too hard.
I have a 92 Aerostar, aka "the Beast." I just changed all the plugs and wires. There's only one way to get to 'em. you may need to remove the cover below your radio (doghouse cover). On the driver's side you just have to bust your knuckles and change sockets a lot. On the passanger side, you should probably reach through the wheel well. I found it easiest to do it that way. It helps to have 2 people. One can help guide the sockets onto the plugs, cause they're impossible to see from the wheel well. Good luck
Going through the fender well on the passenger side is the best way for the first two plugs, but I found the back plug was easier accessed underneath the passenger side of the van by snaking your arm up between the exhaust (engine cool of course). Some extensions and a swivel for your socket wrench will most likely be needed, and the two-man job is a very good idea.
BTW... You will also need to jack up the passenger side of the van, pull the wheel off, and support vehicle with a jack stand.
Quite simply - do them one at a time!!!! Don't overtighten gasketless plugs. I recall something like 1/16 turn after they bottom out.
Trick - use a piece of rubber hose to start a new plug in till you are sure you are NOT cross threaded, before you put any wrench force on it. Good luck,
Tom Greenleaf - MetroWest Boston - USA
I have to plead "I don't know" so mark them using letters - ABCDEF and write down whether you went top to bottom or whatever and which letter goes to which cyl if you are changing wires and get all screwed up it can save hours of guessing. Using letters instead of #s will save further confusion with the real #s. Still best to go one at a time, Good luck,
Tom Greenleaf - MetroWest Boston - USA
James Michael, July 2005
