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Old 02-25-2019, 05:31 PM   #1
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Replacing coil packs

Was replacing the rest of the coil packs today on my 2002 5.4L. Ran into two problems that I need some help with.

1. What is the easiest way to access the coil pack on number 2 cylinder, from the front or the rear of the engine? It looks very tight to get my hand in there either way.

2. The screw that holds the number 5 coil pack in place does not want to back out. It is holding the coil packtight to its mounting point. It rotates with a ratchet but does not unscrew. Anyone run into this before?
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Old 02-26-2019, 04:53 AM   #2
JWA
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Technically the #2 cylinder would be passenger side just behind the very front plug and COP. On my three 5.4's that's one of the easier ones to access although it might require temporarily moving a few heater or vacuum hoses out of the way. I remove the entire air cleaner assembly, sometimes from the throttle body forward which results in an unbelievable amount of room. The only tools needed are 7mm & 8mm sockets for the various bolts and clamps holding the intake air ducting together. If you go this route remember to disconnect the MAF sensor connector found on the bottle of the air filter housing.

Here's the 5.4 cylinder numbering scheme:



A COP bolt that turns but doesn't back out means the brass insert pressed into the plastic intake manifold has "stripped" and turning with the bolt. I can't help with any usable advice how to remove it all at this point but when it is out a thorough cleaning and degreasing of the hole along with some JB Weld should be enough to hold the COP to the intake well enough for many more miles.

One word of caution with the JB Weld or any adhesive for this repair: make very, VERY sure you install the proper bolt coated with a lubricant to prevent the adhesive from seeping onto the bolt threads and locking that irreversibly onto the brass insert.

I also use a dab of anti-seize on the COP bolts whenever they're out for anything. Any one that shows signs of even the smallest damage or resist coming out are are replaced with Ford parts---not cheap but much less costly than a new intake.
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Old 02-26-2019, 01:15 PM   #3
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Thanks for the tips JWA. Got number 2 changed this morning. It took longer than the others. If I was going to do it again I would remove number 1 then remove and replace 2 and then install number 1. Likewise with 3 and 4. It also helped to remove the injector electrical plugs to get more finger room in the bolt area and to grab the coil. The ones on the drivers side have more access so they are easier to remove.

Of the seven I took out only two came out with the boot attached. Had to reach in with a pair of pliers to pull the old boot out. They did not want to release.

It was about 35F when I was doing this so I started the engine and let it warm up. The radiated heat from the engine kept my fingers warm and leaning over the radiator kept the rest of me cozy as well.

Think I will talk with my mechanic to see if he wants to figure out how to change number 5.
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