Rear Plug 93 Aerostar

[chulok56]

Ok.... Sorry for the post again. But how does on change the rear plug on the pass side of a 93 Aerostar XLT 3 l.? That is the only one that I can not get. Any Ideas on how to get it and change it? Or do I need a Song and a Prayer also?

[Knifeblade]

I'm having the same hassle. I haven't tried it yet, but a mechanic suggested, with a serious face btw, to line up a hole through the inner firewall that gets a wrench and plug socket into it, and then drill the hole. He said make the hole around 2", at least, for wiggle room, and then buy a grommet or some other plug to close it back up when done.

I'm seriuosly thinking of doing it, soon, the damn thing looks impossible from the compartment!!!!!!!!!!!!! GRRRRRRRRRRRRRR, LOL.

[Davescort97]

The driver's side front 2 are accessed from under the hood. I drilled a 1 1/2 inch hole near the gas pedal and one more to the opposite side beneath the engine cover to reach the rear plug. The passenger side front 2 plugs can be seen by looking in the wheel well and you will see the plugs just past the top of the frame rail. The rear plug can be reached by the access hole drilled earler. It is best to start by raising the hood and locating the plugs, then take off the interior engine cover. To remove the cover, remove the console cup holder, then the electronic module just above the cup holders. The module is held by 2 5/16 nuts. When you have the cover off and the rear spark plug location is seen drill the hole mentioned before by carefully locating the drill hole start location by looking at the area adjacent to the sparkplug. You have to cut back the rug insulation, then move the carpet down so you can drill the hole. Use the largest bit you have and finish it with a round file. Worked great for me. I plugged the holes with rubber plugs. Use a spark plug socket, 3/8 inch drive ratchet with a long extension used through the access hole and use a flex coupling on the others.

[knelleken]

what i can tell you is this,
DONT DRILL ANY MORE HOLES THROUGH THE FIRE WALL PERIOD......your thinking way to hard at that point. If i recall, you would go from the finder well or underneath.

[Davescort97]

I hope you are right, but rather than fight it for 2 hours it only takes 5 minutes to drill the hole which doesn't hurt anything if you plug it afterwards, then next time.........

[Knifeblade]

Originally Posted by knelleken

what i can tell you is this,
DONT DRILL ANY MORE HOLES THROUGH THE FIRE WALL PERIOD......your thinking way to hard at that point. If i recall, you would go from the finder well or underneath.

Good point, but I've tried to get to the rears from underneath and every other way. I have slim, long arms and can't do it without a lot of time and profane statements. Easiest is to drill the holes.

[tookalook]

take the dog house off its right there. I have done it lots of times you have to take the drink holder out (2 screws) pop the clips jimmy the cover out and there they are.

[bsr2002]

Originally Posted by Davescort97

The driver's side front 2 are accessed from under the hood. I drilled a 1 1/2 inch hole near the gas pedal and one more to the opposite side beneath the engine cover to reach the rear plug. The passenger side front 2 plugs can be seen by looking in the wheel well and you will see the plugs just past the top of the frame rail. The rear plug can be reached by the access hole drilled earler. It is best to start by raising the hood and locating the plugs, then take off the interior engine cover. To remove the cover, remove the console cup holder, then the electronic module just above the cup holders. The module is held by 2 5/16 nuts. When you have the cover off and the rear spark plug location is seen drill the hole mentioned before by carefully locating the drill hole start location by looking at the area adjacent to the sparkplug. You have to cut back the rug insulation, then move the carpet down so you can drill the hole. Use the largest bit you have and finish it with a round file. Worked great for me. I plugged the holes with rubber plugs. Use a spark plug socket, 3/8 inch drive ratchet with a long extension used through the access hole and use a flex coupling on the others.

Did you use regular drill bit to drill your holes?

[rhandwor]

Originally Posted by bsr2002

Did you use regular drill bit to drill your holes?

I always use a metal hole saw when cutting through thin metal. You can buy single saws at the local hardware. They are also needed to change some window motors but smaller 5/8 inch.
Remember you will need a metal cover self tapping screws and silicon as a gasket or your feet will freeze in this weather. Remove the floor covering first.

[bsr2002]

This is a video I made with me getting to that plug...lolz

http://www.youtube.com/watch?v=xbS5JthGhXE

[RahX]

I've never had problems going through the wheel well if you jack it up and let the suspension hang with the tires off. Extensions do wonders.

[bsr2002]

Originally Posted by RahX

I've never had problems going through the wheel well if you jack it up and let the suspension hang with the tires off. Extensions do wonders.

Yeah for the first two not the third 3.0 engine 1997