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Ford WindstarIntroduced in the mid-1990s, the front-wheel-drive Ford Windstar minivan campaigned with an emphasis on, and reputation for, safety. And in the hotly contested family minivan market of the time, that was an especially solid piece of ground to be on. As long as buyers didn't need to haul adults in back on a regular basis, the Windstar served a family's needs just fine.
The van drove perfectly fine until I filled the tank three days ago. Later that afternoon, I noticed a hesitation while driving it, almost like a chugging-type feeling and it was worse when sitting idle. No engine lights came on, though, so AutoZone said they really couldn't check for anything. Took it in to the repair shop, they replaced the coil pack but said the manifold needs replaced and they can't get the part from Ford because Ford stopped production (is this true?). Also said it would very expensive anyway, and the van has 114,000 miles on it so I'm not sure how much money I want to put in it. They made it sound like a pretty big deal, and I'm not up to that, truthfully.
Drove it home and it drives better but still has a really rough idle. Today, the emissions control light came on for the first time. Went back to the shop where they cleaned out carbon build up and sent us on our way. The light had gone out but by the time I drove about three miles, it came back on. The engine seems to rev itself when sitting idle in the garage; it's really kind of creepy! It's also going through gas like crazy - I went from getting about 17 mpg city to 13.6 mpg. We made an appointment to take it to the Ford dealer on Monday, without telling them what we've been through and what we were told, but I was just wondering it any of this sounded right to anyone here? Now that the light came on, we may take it back to AutoZone to see what it reads.
How long have you owned the van, it sounds like you just got it and only filled it up once... maybe twice.
Anyway, my 1998 is having a similar problems as you. Ever since I bought a new engine. It actually is doing better, but every once and a while it has a bad day, where it stalls and stuff. The guy who put the engine in, said He can't figure it out. He tried a few things... coil pack, Crankshaft pos. sensor, throttle pos. sensor, and a few other things.
I'd have to tell you the chances of you needing a new manifold are very slim, unless you have a super/turbocharger in the van. I'd suggest replacing the IMRC gaskets, and inspect the fuel injector o-rings. You can do it yourself with a gasket remover/installer tool, gaskets, a torque wrench, and a few socket wrenches. I still gotta do my upper IMRC gaskets, because the guy that did my engine told me he replaced the lower gaskets, but not the upper gaskets. (He thought they were ok...but I think they may be bad). In my van, I'm wondering if the O2 sensors are bad, or the catalytic convertors are clogged.
I am also wondering it you got some bad gas in the tank, or maybe you and me have a related issue. Ford can definitely get you new manifolds, but they are pretty much $1500 (get a new-to-you windstar for that). If you really need manifolds (you most likely don't) go find a junkyard and buy them for ~$30. Try getting the gaskets changed out... unless you think it may be something else. Ask yourself: What parts may have been changed to cause the problem?
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1998 Ford Windstar GL 3.8L 253,100 miles
2005 Toyota Prius Package 6 1.5L 135,000 miles
2006 Toyota Sienna LE 3.3L 36,000 miles
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We've had the van four years and, beyond the usual Windstar stuff with the doors and a horn issue, engine-wise it's been fine (replaced the battery twice but that's no biggie.)
The guy at the shop mentioned replacing gaskets as the next step but still seemed convinced we needed a manifold. The only thing replaced on the van in the past two weeks have been the battery and the coil pack. As I said, it ran fine until I put the gas in last Tuesday and the problem really hasn't been solved completely since the coil pack was installed. It doesn't chug while driving but it's awful while sitting at a light or in traffic.
We did take it to AutoZone last night and it read PO 410 EGR flow insufficient and PO 171 System too lean (Bank 1). They suggested replacing the oxygen sensor, which we bought and my husband is trying to do now. He's having a hard time getting the old sensor out (he's not very mechanically inclined at ALL, which bodes well for this whole scenario). Any ideas on the code readings?
**UPDATE**
My husband changed the O2 sensor (yay for him) and it helped a very little, but then the A/C decided to start blowing out from the defroster vent, not the front vents. He messed around with the hoses and connections under the dash (behind the CD holder under the stereo system), blew on some connections and, voila, all problems solved, including the terrible idling and chugging... EXCEPT...we're still getting a PO 171 code from the CEL. The van runs perfectly fine now -better than before, actually - so any thoughts on this new development?
Last edited by Bree26; 07-20-2008 at 02:02 PM.
Reason: update post
Yeah... I'd say you were lucky that the vacuum leak got bad enough that it caused a malfunction that was obvious.
When I said, "My first guesses would be vacuum leak(s) or a bad IAC." I wasn't thinking of the little one's under the dash that actuate the controls for the front and rear a/c or heat.
Yeah... I'd say you were lucky that the vacuum leak got bad enough that it caused a malfunction that was obvious.
When I said, "My first guesses would be vacuum leak(s) or a bad IAC." I wasn't thinking of the little one's under the dash that actuate the controls for the front and rear a/c or heat.
Well, I'm not sure that was the entire solution. As I said before, we still have the CEL light on, even though the engine runs 100% better than when we got it back from the garage. AutoZone said it's still the PO171 "system too lean" code. We replaced one O2 sensor; in reading a newer thread here concerning the same code, does that mean we need to replace the second as well? I was assuming the CEL would clear itself out once the problem seemed to be resolved. Was I wrong to assume that? I hate to take it to the dealer if we don't need to, but if the light stays on, I'm thinking we need to.
you are still getting the o2 code may be because you have 2 oxeygen sensors the one in exaust manafold and one in the in or near the catalyitc converter under the van they say you should always replace them in pairs to clear the codes from your computer disconnect your battery terminal for thirty seconds then put it back and then check codes again.
We've had the van four years and, beyond the usual Windstar stuff with the doors and a horn issue, engine-wise it's been fine (replaced the battery twice but that's no biggie.)
The guy at the shop mentioned replacing gaskets as the next step but still seemed convinced we needed a manifold. The only thing replaced on the van in the past two weeks have been the battery and the coil pack. As I said, it ran fine until I put the gas in last Tuesday and the problem really hasn't been solved completely since the coil pack was installed. It doesn't chug while driving but it's awful while sitting at a light or in traffic.
We did take it to AutoZone last night and it read PO 410 EGR flow insufficient and PO 171 System too lean (Bank 1). They suggested replacing the oxygen sensor, which we bought and my husband is trying to do now. He's having a hard time getting the old sensor out (he's not very mechanically inclined at ALL, which bodes well for this whole scenario). Any ideas on the code readings?
**UPDATE**
My husband changed the O2 sensor (yay for him) and it helped a very little, but then the A/C decided to start blowing out from the defroster vent, not the front vents. He messed around with the hoses and connections under the dash (behind the CD holder under the stereo system), blew on some connections and, voila, all problems solved, including the terrible idling and chugging... EXCEPT...we're still getting a PO 171 code from the CEL. The van runs perfectly fine now -better than before, actually - so any thoughts on this new development?
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2001 SEL idle problems 
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