96 Windstar: Head Gasket Problem

[Windstar-OHIO]

At about 98,000 mi I frequently had to refill the overflow reservoir with antifreeze. Seemed like there was always excess moisture coming out of the tailpipe, but no noticeable antifreeze in the engine oil. Took it in for a pressure check, and it held pressure fine. At about 99,000 mi, started to notice antifreeze on the garage floor, mostly under the passenger side of the engine. Took it back in and had the timing cover gasket replaced, which took care of the antifreeze on the garage floor. However, since that repair, I still have had to continually refill reservoir (about 1 gallon over 5,000 mi). Again, I had the system checked for leaks, held pressure again (no apparent leaks anywhere), and so, I believe I have a blown head gasket. Correct? The local Ford dealers are asking about $1,600 to replace both head gaskets. However, one hightly reputable independent garage advised me not to have this done because it was their experience that these 3.8 V-6 engines frequently 'blew' (developed 'lower' engine problems) after the head gaskets were replaced. There are many complaints posted on various sites about the Windstar's problems with blown headgaskets, and overall problems with the 3.8 -V6 engine in 94-96 Windstars. Does anybody have any experience that would help me decide whether to have the head gaskets replaced or dump the van by trading it in??? I'm the original owner, and other than the engine, it's in excellent condition with only 106,000 miles. THANKS for your advice!!!!

[rvluver]

Here is my story: I have a '96 LX presently at 98000 miles. Looks, runs like new.
In 2004 (89000m) I hauled a trailer (Pop-up) from Florida to Washington State and back. Despite it being a small trailer, it put a great strain on the van for that distance.
I had two problems: The EGR ports plugged up in the manifold, rought performance: cost to repair 300.00. The headgasket started leaking after I returned, just like your symptoms.
Had them replaced at Ford dealership: cost 1200.00 in Florida.
I consider that a lot cheaper than giving up a perfectly good van and start with something unknown. There was a recall in the early years for this on some models from some plants.

I don't think it's a big deal. Have had no other major expenses in ten years.
I'll keep mine until it croaks. carson FL

[goon]

if you find out its a head gasket do both heads it only takes about 1/2 hour to remove the other head, I have done lots of them and get them plained and pressure tested at the machine shop,

[Windstar-OHIO]

Just wanted to provide an update. Found that the problem was not a head gasket, but instead, a blown lower intake manifold gasket. It was blown on the back side of the engine (towards the firewall), so it was difficult to detect...but a mirror on an extension did the trick. Hope this post helps others that have a mysterious antifreeze leak. Replace the lower intake gasket cost a lot less than replacing a head gasket!

[mark v]

Thanks for the heads up. I just dumped some Alumaseal Gold Eagle - AlumAseal in mine and the leak went away.