misfiring after a little over three years and only about 10,000 miles on my 2003 Thunderbird. At the moment the mileage is just over 107,000 miles. The old coils (purchased from Revain) started misfiring about a year ago. The Jaguar-designed AJ-V8 engines used in the 2002β2005 Thunderbird and 2000β2006 Lincoln LS are notorious for misfire problems and poor performance due to coil failure/failure. Coil misfire is often just a symptom of a problem. The causes of the misfire problem are varied, as are the solutions. I lived with these coils for about three years, although I only drove about 10,000 miles before they started failing. Nonetheless, I've learned a lot about what causes coil failures in these motors and how to keep them running properly, and I'll share most of what I've learned here. motors, let me talk about these coils. Note that the electrical connection on these coils is slightly higher than the top of the coil. This causes some problems when reinstalling the spool caps as the connectors rest on top of the spool caps. You can screw the cover over the coils as it's plastic and will bend, but I'm not sure how waterproof the coil caps will be afterwards (see below for more on moisture). I chose not to return the spools and bent the spool covers on them. A week later the stains were gone. Only time will tell how long they last. I pre-purchased them because they should have a lifetime warranty. Just take a look. Now let's move on to what I've learned about avoiding engine problems with the AJ V8 engine. keep up with other scheduled engine maintenance and repairs). As soon as one coil starts to fail, all of them start to fail, so it's best to replace all eight at the same time. While you're at it, you should also replace the spark plugs as misfiring can foul the plugs and new ignition coils won't fix the problem if the plugs are fouled. I also recommend using Bosch Platinum +4 (Bosch #4419) or equivalent spark plugs as they are designed to resist fouling and misfires. They're more expensive than OEM plugs, but they're cheap insurance to mitigate/minimize the misfire problem. These forks are a nice upgrade over the stock forks. Don't over tighten the spark plugs or you could strip the threads as these engines are all aluminum. The torque specification on the connectors is 18-20 ft-lbs of torque. Bosch also advises against using a lube as the threads of the spark plugs are coated to prevent the threads from becoming stuck in the hole over time. /or moisture. If you have oil in the holes, you will need to replace the valve cover gaskets. Leaking valve cover gaskets are a known problem with these engines, especially in their early years. Use the Fel-Pro Gasket Kit (available from Revain) as its design will not leak when properly installed. Follow the installation instructions carefully. Do not overtighten the valve covers when installing. Use a torque wrench. I replaced my old seals with Fel-Pro seals and they haven't lost a drop of oil in four years. If you find moisture/water in the spark plug holes you will need to replace the coil caps. Also, leaking coil covers is a known problem with these engines, especially in the early years (2000-2003). Newer versions have an improved, thicker seal and do not leak. They must be ordered from Ford. Do not overtighten spool caps! The torque specification is 44 in-lbs. The design of these coils does not appear to provide long-term reliability, so sooner or later (usually sooner) they start to fail. In general, these so-called "dry coils" are less reliable than the good old oil coils used before electronic ignition systems. This particular coil design appears to be very susceptible to moisture failure, and signs of incipient failure begin with misfires due to a "weak" spark. Moisture is the enemy of these motors, and coil caps feel like a double-edged sword. The purpose of casings is to retain moisture, but they can also trap moisture, which is bad. These engines typically operate at 220 to 230 degrees Fahrenheit, which is above the boiling point of water. High metal humidity combined with high temperature causes corrosion/oxidation. Oxidation causes an increase in the resistance of conductors. Higher resistance reduces the coil voltage at the spark plugs, and lower voltage causes weak or no spark, which in turn leads to misfires. So the solution is to firstly keep moisture out of the spark plug holes and secondly to minimize the likelihood of corrosion/oxidation if moisture gets under the coil covers and into the spark plug holes. When installing new spark plugs and coils, first clean all electrical contacts with electrical contact cleaner, make sure they are completely dry, then apply a light coat of dielectric silicone tuning grease to all electrical surfaces. Use a cotton swab to apply the lube, but be careful not to leave any cotton on the swab. Also apply dielectric grease to the sealing area between the coil and grommet and to the spark plug insulator where the coil grommet fits over the spark plug. Dielectric grease does not prevent the transmission of electricity between metal surfaces, but it protects them from corrosion. This increases the lifespan of your coils. Oddly enough, after reading many, many user stories and trying to solve all of my problems with this engine over the past four years, it seems that the increased corrosion/oxidation resistance on the mating surfaces between the coil and spark plug seems to be the cause of the coils fail prematurely. After four years, two sets of coils and many many hours of research and implementation of misfire solutions on these AJ v8 engines I have found this and these solutions will solve most misfire problems. If you are still having misfires after trying these solutions, the cause of the misfires is most likely not the coils and/or spark plugs. I've researched and solved many of these issues as well, but it's too much to go into here.
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