Last post on Oct 27, 2006 at 8:51 PM
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Ford Windstar, Van
#1583 of 2608 windstar 3.8 with SES Light
Mar 08, 2005 (9:21 am)
I have a 2001 Windstar with the 3.8 engine. Ford says the SES light is because of vacuum. Mechanic said valve cover and pcv hose need to be replaced. They explained the new baffle in the pcv hose and that the new valve cover will correct problem, also said my 0 rings are shot b/c of the oil that was sucked in corroded them further causing vacuum leak. They want $600 and up to fix. Can anyone tell me what the corrected part numbers are for these and if my husband could do repairs himself. He knows his way around all older engines very well, but he hasn't worked on these newer electrical beasts.
#1584 of 2608 Re: windstar 3.8 with SES Light [luv2cruz]
Mar 08, 2005 (12:09 pm)
It's not a difficult repair if he's mechanically inclined. I don't know the part numbers, you may ask a dealer service dept.
#1585 of 2608 Re: windstar 3.8 with SES Light [luv2cruz]
Mar 08, 2005 (4:13 pm)
The database I have here at home doesn't cover the 2001 model year, but here's the info for '99:
Disconnect the negative battery cable.
Label and disconnect the ignition wires from the spark plugs.
Remove the ignition wire brackets from the valve cover retaining studs.
Remove the upper intake manifold.
To remove the forward valve cover:
- Disconnect the crankcase ventilation tube.
- Remove the oil filler cap.
- Remove the alternator wiring harness from the valve cover studs.
To remove the rear valve cover:
- Remove the cowl vent panel.
- Position the air cleaner assembly aside.
- Remove the PCV valve.
- Note bolt and stud locations prior to removing the valve cover.
- Loosen the valve cover retaining bolts and studs
- Remove the valve cover.
Clean all gasket mating surfaces thoroughly.
Lubricate all bolt and stud threads prior to installation.
Install new valve cover gasket and align fastener holes.
Position valve cover on cylinder head and tighten bolts in sequence to 71-97 inch lbs. (8-11 Nm).
To install the forward valve cover:
- Install the alternator wiring harness on the valve cover studs.
- Install the oil filler cap.
- Connect the crankcase ventilation tube.
To install the rear valve cover:
- Install the air cleaner assembly.
- Install the PCV valve.
- Install the cowl vent panel.
Install the upper intake manifold.
Install the ignition wires.
Connect the negative battery cable.
Start the engine and check for leaks.
#1586 of 2608 Re: 98 Windstar, electrical problems [garyp]
Mar 09, 2005 (4:57 pm)
This is a great website! I had the problem with my 98 windstar that the door ajar light was on and the door chimes going off and on. I read a reply on this website - it said to use WD-40 on the black door latches and contacts below - I did it and it worked. Give it a try.
#1587 of 2608 Re: 98 Windstar, electrical problems [segmiler]
Mar 09, 2005 (8:53 pm)
Works for most Fords. The switches are in the latches, the grease dries out and hardens, sticks the switches.
#1588 of 2608 Re: windstar 3.8 with SES Light [alcan]
Mar 10, 2005 (6:34 am)
Thanks for all the help, He's going to do the repairs himself. We were finally able to download a copy of the TSB 03-16-1 that goes with this repair and that along with the above should make everything go pretty smooth. Again, I can't say "thanks to y'all" enough!
#1589 of 2608 PCV update
Mar 12, 2005 (4:44 pm)
Can the updated PCV valve/line be retrofitted without doing valve covers.
#1590 of 2608 Re: Heater core is dead at 138K [windstarhater]
Mar 12, 2005 (8:12 pm)
I have a 1995 Windstar and hate it too. I have had nothing but problems with it from early on. I take very good care of my cars (oil chg every 3 - 6,000 miles, all scheduled maint on or before schedule, drive it gently, etc). The famous 1995 head gaskets blew once at 88,000 miles (Ford to their credit voluntarily extended the warrenty and covered it). They (gaskets) blew again at 114,000 miles. Electrical problems, wind noise, etc, etc. There is no excuse for makine a car in America that cant last 100,000 miles without extesnive engine work when the owner takes care of it. So, I broke down and got a 2005 Honda Odyssey EX - L with DVD. I got it for $3,000 of MSRP and figure it is one of the most reliable well build mini vans around. My Dad has a 1993 Acura Legend that he has smashed up twice, drove through the streets of Brooklyn and New Jersey, barely took care of and I just put $3,500 into it and it drives like a Honda Tank. The engine is strong and body has held up well. My Windstar looks like its been abandoned in a junk yard for 3 years and while I dont garage it, I do wax and clean it. That's the difference bwteeen a Ford and a Honda.
#1591 of 2608 Re: 98 Windstar, electrical problems [garyp]
Mar 13, 2005 (7:43 pm)
I own the same vehicle with the same problems as you mention in 1,2&3 above. The problem is most likely due to sticking door latches that become gummed up with dirt etc. Try cleaning each door latch by spraying with an aerosol de-greaser and then spray with WD40 or some other lubricant. I did the last year and the problems disappeared.
#1592 of 2608 Re: PCV update [hault]
Mar 13, 2005 (8:57 pm)
If the valve cover isn't baffled, it needs to be replaced. The unbaffled cover will still pass oil through the PCV system, and cause big problems as the engine carbons up.