1996 Ford Windstar

[deputydawg]

Anyone able to assist me here. I am looking for a site showing how to replace the head gasket on my 96 Windstar 3.8 Litre. Mostly need to know if there are any tips to watch for, dangers to be careful of, and the torque specs on everything involved.<br />Thanks...

 

[AK_Chappy]

Re: 1996 Ford Windstar

Yeah,<br />Start with the .45 and blast some holes in it. Work your way up to the 30/06, then to the 300 Win Mag.<br /><br />I had the head gaskets done in my 1995 two years ago. Still have problems with it. After talking to some auto tech friends. They all had the same story. The Ford 3.8, especially that year range, is a POS.<br /><br />Other than that, sorry. I don't have any useful information. <br /><br />AK Chappy

 

[Bob_VT]

Re: 1996 Ford Windstar

I hear that the older 3.0 and 3.8 are notorious for warping. Once you get the head off have it checked throughly. Look at these links...<br /><br /> http://www.allfordmustangs.com/Detailed/650.shtml <br /><br /> http://www.babcox.com/editorial/ar/ar90134.htm <br /><br />They should be the same specs.

 

[deputydawg]

Re: 1996 Ford Windstar

Thanks guys.<br /><br />Chappy I like your idea, and have had fantasies about it. Problem is I owe too much to junk it. Wanted to shove it off the bridge into the river. That would be cool to watch, but then my insurance would probably go up.<br /><br />The 3.8 engines in 94 and 95 had a problem. Ford extended the warranties on these to cover the head gaskets for extra years and miles. Supposedly in 1996 they fixed the problem but the early 96's had a few lemons still. <br /><br />Can't complein though, 158,000 miles and have never done anything mechanical to it at all. Tires, 1 set of brakes, and batteries is all I have put into it so it has been good to us.

 

[DJ]

Re: 1996 Ford Windstar

The repair is pretty straightforward. Just make sure you have the heads checked thoroughly.<br /><br />You MUST replace the headbolts. The tricky part is the front cover gasket. Not that it is hard to do, just it's a big gasket.<br /><br />BTW, this is a NON issue for units that have the cooling system serviced reqularly-yearly or every 24K.

 

[deputydawg]

Re: 1996 Ford Windstar

I service the cooling system in all my cars every spring....but it was a used vehicle so who knows prior to my owning it. <br /><br />Got the heads off today. The left head gasket looks like it either wasn't on straight or like the corner of the dead was dropped onto the gasket during install. The metal ring on the cylinder hole was smashed in a small spot. Looks like it started leaking there. <br /><br />Heads should be off to the machine shop to be checked out Tuesday.

 

[LubeDude]

Re: 1996 Ford Windstar

I hope your heads are ok, seems they almost always warp. Take the plunge and buy new head bolts, Unfortunatly this is a have to and they are spendy!!!!!!!!!!!<br /><br />You need to follow the torgue paterns and sequence to a "T"!!! And its a strange one, you may need a manual to get it right.<br /><br />The coolant replacement every other year is also a must as DJ said.

 

[deputydawg]

Re: 1996 Ford Windstar

Ordered new head bolts yesterday, picked them up today. Only $20 per side. I always replace the head bolts on every removal I do.<br />The left head is cleaned up, no cracks, checked with a straight edge. The tolerance is .003 per 6 inches, it is not even warped to .001 so that is good. Still sending them to have them checked with all of the miles.<br />Was very impressed to find no ridge in the cylinder walls, no scoring or scratches visible, and still able to see the cross pattern on the cylinder walls. Looks great for the miles.

 

[LubeDude]

Re: 1996 Ford Windstar

You should have the heads suffaced anyway, just have them do a slight cut to true them. A straight edge is not sufficient.

 

[deputydawg]

Re: 1996 Ford Windstar

Got it back up and running. All is good with the world except for the fact I drive a minivan!<br /><br />Changed oil at 10 miles, now have 120 miles on it and need to change it again to make sure the water doesn't sit there and damage bearings.<br /><br />Head gasket was all it took. Machine shop looked the heads over good and did their thing to them. No warping or cracks. Runs better than it has in months. I'm thinking it was seaping a little for a while.

 

[LubeDude]

Re: 1996 Ford Windstar

Good to hear, glad things went well, How did you like the way you have to torque the heads????

 

[deputydawg]

Re: 1996 Ford Windstar

It didn't make much sense. The progressive torque made sense and the sequence did, but what is with the final torque? Go to 50 ft.lbs. or whatever, back off 2 to 3 turns, torque to something else, then tighten another 90 degrees? <br /><br />Hopefully I can get another few years out of it. Now I have a CV joint in my wifes 94 Bonneville going out. I am building a wood stove for my shop. As soon as I finish that it is on to the Bonny. Always something.