The joys of working on your own vehicle...

Oct 9, 1999
15,216
3
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So i lost my AC a few weeks back, initially i thought fan resistor pack but it did not show the symptoms of the fan resistor pack going out since if that was blown then it would only work on speed 4. So a bit of fooling around I figured what the heck, check the switches, sure enough it was the fan switch and not the resistor pack.



So since I had bought both parts, i figured might as well replace both. Well lets put it this way.. I only managed to do one of them today. Whoever designed the connectors for the focus must be shot, cause the repair manual says, put small screw driver and push, yeah right, i broke the fucker.


Anyway i replaced it, thank god that I have a bucketload of tools I was able to get it out and replace the fan switch, the resistor pack, thats for another day. That is yet to fail (but knowing my car, thats not too far behind). In the process of reassembly, i lost a screw. I dont know where it went, but its somewhere in my center console now. I also cant seem to take out my fricking headunit (cdplayer) removal tool. Its stuck on one side and it wont come out.


Lesson of the day - next time you screwing back something into a tight corner, use fingers first to thread it in or use a magnetic tip

Next up, i thought while I am at it, replace spark plugs. I need to go for a smog check soon, and with 160,000 miles, every bit helps. So I started replacing the plugs and boy oh boy.. 2 of them are stuck inside the cylinder, so i had to breakout my torque wrench, but its not made to be used as a breaker bar, so i need a new torque wrench now, this one is probably out of spec after today.



Now the last time I had changed my plugs were at 60000 or so odd miles. At 120,000 the mechanic who performed the major service said the plugs were replaced (duly noted on my repair log). Well turns out he hadnt and those were the plugs that I had on there for 100000 miles (I know cause he said he put in Motorcraft plugs, I had Autolite double platinum in there). The wires I know were changed at 120,000 since i did those myself. I am glad I replaced the plugs cause some of them were in pretty bad state, the contact point on them was so worn, so it was a good time to replace. Ofcourse stupid ole me lost the gapping tool, i saw i had it before i went to autozone to pick up some dielectric grease and anti-seize but when i got back that gapping tool was no where to be found, and i didnt want to make another trip. So I pulled out my handy dandy feeler gauge valve measuring tool (of course i didnt have 0.054" in there). I couldnt gap them right with the feeler gauges but i know its now not at factory spec 0.054" but 0.048", oh well its running. Turns out the old plugs that i pulled out were also at 0.048", i wonder if i ever gapped them the last time around.


Lesson of the day have an organized tool box and have all tools you need nearby, so you dont go hunting for a missing tool that was once there and use a lot of anti-seize and check the tightness of your bolts.




Well the car starts and runs, but now i got to figure out what the rattle I am hearing. I'll take it for a nice test drive to see how she does. I hope its not something else loose, but I think it could be the exhaust mount bracket (known to get loose at times). Oh well 160,000 miles, if blondie can get to another 20,000 I am happy, that will give me enough time to wait until the plug -in hybrids start showing up for the 2009 year.




Now off to get myself squeaky clean.. thank god for latex gloves, my hands arent all that dirty.

Remember folks, working on your vehicle can be a lot of joy but you got to have a heck lot of patience and a calm head when something goes wrong and you're stuck!
 

njmodi

Golden Member
Dec 13, 2001
1,188
1
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Did you put anti-seize on your new plugs? also - perhaps they were previous over-tightened (when you last installed)... most new cars have their plugs first changed at 100k+ - and there is usually no issue in getting them broken loose.

My biggest problem here in the snow-belt is rust...
 

BUTCH1

Lifer
Jul 15, 2000
20,433
1,769
126
Originally posted by: njmodi
Did you put anti-seize on your new plugs? also - perhaps they were previous over-tightened (when you last installed)... most new cars have their plugs first changed at 100k+ - and there is usually no issue in getting them broken loose.

My biggest problem here in the snow-belt is rust...

Depends on how long it takes to get to 100K, if it takes 10 yrs. to do
so plugs can be a bitch to get out!
 
Oct 9, 1999
15,216
3
81
had a fun day?

How are your plugs stuck?
Can't you get pre gaped plugs?

Yeah so much fun.. :sun:

Did you put anti-seize on your new plugs? also - perhaps they were previous over-tightened (when you last installed)... most new cars have their plugs first changed at 100k+ - and there is usually no issue in getting them broken loose.

My biggest problem here in the snow-belt is rust...

Yes I put anti-seize on the new plugs, thats why i had to go to autozone for, anti-seize and di-electric grease for the boots. I doubt i over tightened them cause since the last time I changed the plugs it the top end was taken apart and rebuilt (valve was sticking) so it was the mechanic who took them apart.

Well I know most cars require plugs to be changed at 100K, hell my car required it at 100K, but i did it at 60 due to a misfire (arcing between the wires and the block). I guess it was just that it was stuck really badly, but using greater leverage of a longer breaker bar / torque wrench works wonders. I am going to keep this torque wrench for breaker bar duties and buy another one (preferably screw type, this one has a scale).

The time taken between the last set of plugs and now. I replaced at 60K was around mid-2004. The top end rebuild was last year in January 2007, 120,000 mile service was in June 2006.

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I just got back from a drive, its running good. Power seems to have come back, or rather power delivery is much smoother. I am sure it will pass smog easily day after tomorrow. I'll give it a day to break in the plugs. I put on 60 miles tonight just to break her in and make sure everything is working alright. If this car really lasts the miles, I will be more than happy. She has gotten me though everywhere without really much trouble, and frankly its not worth any for a tradein, so i'll drive it to its end. Or I will buy a newer car later and then find some extra $$ to rebuild it and make it a track / performance car with new components, new engine etc etc.