Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1996E 350 VAN V8-460 7.5LREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTIGNITION SYSTEMSPARK PLUGSERVICE AND REPAIR
1996 Ford E 350 Van V8-460 7.5L
Spark Plug: Service and Repair
1996 Ford E 350 Van V8-460 7.5LSECTION Service and Repair
Removal
1. Remove air cleaner inlet tube assembly.
2. Remove distributor to spark plug wire from spark plug using Spark Plug Wire Remover T74P-6666-A, or equivalent.
3. Remove any dirt or foreign material from spark plug areas of cylinder head with compressed air. Remove spark plugs from cylinder block using appropriate socket, extension and socket wrench.
Installation
1. Refer to the Spark Plug Inspection Chart to determine spark plug condition. Replace spark plugs as required.
2. Check and set the spark plug electrode gap to: 1.07-1.17 mm (0.042-0.046 inch) using an appropriate gapping tool.
3. Install spark plugs into cylinder block. For V-8 engines, tighten to 9-20 Nm (7-15 lb ft).
4. Coat entire interior surface of ignition wire boot with Silicone Dielectric Compound (WA-10) D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Install onto proper spark plug. Make sure spark plug wire boot is completely seated.
5. Install air cleaner outlet tube and inside engine cover, if required.
6. Start engine and check for proper operation.
1. Remove air cleaner inlet tube assembly.
Spark Plug Wire Remover:
2. Remove distributor to spark plug wire from spark plug using Spark Plug Wire Remover T74P-6666-A, or equivalent.
3. Remove any dirt or foreign material from spark plug areas of cylinder head with compressed air. Remove spark plugs from cylinder block using appropriate socket, extension and socket wrench.
Installation
1. Refer to the Spark Plug Inspection Chart to determine spark plug condition. Replace spark plugs as required.
Gapping Spark Plug:
2. Check and set the spark plug electrode gap to: 1.07-1.17 mm (0.042-0.046 inch) using an appropriate gapping tool.
3. Install spark plugs into cylinder block. For V-8 engines, tighten to 9-20 Nm (7-15 lb ft).
4. Coat entire interior surface of ignition wire boot with Silicone Dielectric Compound (WA-10) D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Install onto proper spark plug. Make sure spark plug wire boot is completely seated.
5. Install air cleaner outlet tube and inside engine cover, if required.
6. Start engine and check for proper operation.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.