Good info, it's surprising how often ford decides to change something that isn't broken. After this procedure and all others are exhausted, check your ECM. Mine was good except for the cold start scenario. Which made it seem like a bad IAC. You can loose data over time in different parts of the ecm.When the engine is cold the IAC should be open. When you start it up cold, pull the connector off the IAC. It's basically a solenoid that engages when cold, and allows fresh air to by-pass the throttle body (which would be closed). If you don't hear the solenoid disengaging and engaging when you disconnect/connect the connector (engine cold) there's an issue with it. Check the pdf file I attached earlier and see if you got a later model IAC. If so, according to the pdf, swapping the two wires should fix it.
You could also connect 12 volts to the IAC to test the solenoid. If it doesn't work, switch the wires and try again. If it doesn't engage with the polarity either way, it's bad. With 80 miles on it, it can't be clogged up.
I don't think so. The whole point of it is to conduct heat off the tfi module and onto the distributor. I'm not sure if anything else can transfer the heat properly, and there's a chance it could overheat.Is there something else I can use?
Napa doesn't have heat sink.