Back In September I pulled the passenger side rocker panel cover off. I had to take care of a small spot of aluminum corrosion on the bottom of the front fender. I used Moeller zinc chromate primer on the bare aluminum - I picked it up at my local West Marine store. I then primed, painted and clear coated the area. I order the paint and clear coat kit off eBay. I cleaned up the light surface rust on rocker panel and use POR15 to seal up those area. I then undercoated the whole rocker panel, edges pinch seams and back side as well. I have been very busy with work this Fall so the driver's side rocker panel will have to wait until Spring.
In October, after having a couple fail soft mode start up conditions, I down loaded the codes, did some research and decided it was time to replace the spark plugs and COP coils. I had already bought the Autolite Iridium XP spark plugs and replacement coils, they had been sitting on a shelf in the garage for a several of months. With only 43K miles on them the original factory parts did not look all that bad. The only one that had an issue was the driver's side rear. The plug and boot showed signs of water intrusion at one time. The O-ring from the oil filler neck tube must be starting to weep/leak - there as some oil under the coil cover panel, but it was not down in the spark plug well yet. I gapped the new plugs at 0.038". I cleaned up the coil cover panels and gaskets and used some clear RTV silicone to seal them up along the front, top and rear edges. The engine now starts up quicker and idles noticeably smoother. There seems to be a little extra zip in the acceleration as well.
Now its November and the mileage on the last few tank fulls seemed a bit low - maybe I was enjoying the improved engine performance a bit too much? Well, it was time to put the winter wheels/snow tires on the car this weekend, so I decided it would be a good time to replace the rear brake rotors and pads as well. Those parts had also been sitting on the shelf in the garage for a while as well. I found the reason for the lower MPG's - there was a frozen caliper slider pin on the passenger rear. I was able to knock the slider pin out of the caliper mounting bracket. It wasn't too bad, so I cleaned it up with a wire wheel. I was also able to clean out the bore of the caliper mounting bracket with the drill press and a couple bits, without enlarging the bore ID. The problem was caused by a damaged rubber bellows boot. Luckily I never throw anything away and found a match from another Ford rear caliper rebuild kit that I had in the spare brake parts drawer. I cleaned up the other slider pins, re-lubricated them with dielectric grease and all is now well. I used a pair of AutoZone Duralast Gold brake rotors (higher carbon content and fully corrosion coated) along with a set of Porterfield R4-S pads to match the pads in the front that I used with the Jaguar 320mm front brake upgrade.
The "disc brake caliper pad & piston wind back tool kit" that I got off eBay sure made the job quick and easy, both to turn the piston down into the caliper and to get the slots in the piston aligned with the knobs on the pad backing plate.
Now I know my the Michelin X-ice Xi3 winter tires are low rolling resistance tires and my Michelin Pilot Sport A/S 3 summer tires are not, but fixing that frozen rear brake caliper with the dragging pad sure made a night and day difference in how the car rolls. Hopefully the MPG will improve as well.
The only thing left before the weather really gets cold/bad/ugly will be a new HD 750 CCA group 66 battery.