A few general maintenance questions...

New member here - I've owned a new 2003 Windstar SE since August of 03 (got a great deal on it with a combination of rebates and A-plan pin). It has been almost trouble free with over 102K on the odometer. I'm interested in doing some 100K maintenance myself and I'm fairly mechanically inclined having worked extensively on Ford's MN-12 cars (89-97 T-Bird and Cougars) including motor and transmission removal and modifications. Some of the maintenance I've already performed on the van (other than normal oil/filter changes) are power steering system flush, 30K regular transmission fluid flushes, tire rotations, etc. I'm looking to change the plugs and wires, most likely removing the upper intake and cleaning any blocked EGR ports. I will double check the LH valve cover for "the hole" as well. I also wish to flush the coolant system as well as a total suspension redo and brake check. I haven't touched the brakes, but I live in a rural area and mostly do highway driving.

Does anyone have tips on changing the plugs/wires or coolant?

Changing plug wires is tricky in the back of the engine compartment. I tried to get back there and ended up taking it to the dealer because I couldn't get to it. $295 later (!), I figured I wussed out too easily and found this wonderful forum. Many posts here (use the search function) refer to putting the van on ramps and getting underneath to reach the plugs and wires. You could also take out the cowling under the windshield and reach over the engine if going under there isn't to your liking.

The coolant flush is a mystery to me still, even after reading umpteen posts on coolant. The '03 has a closed system (no rad cap, just an overflow tank), so the traditional Prestone 'T'-fitting flush and fill kit may not work since you have to fill at the cap to flush. The owner's manual specifies Specialty Gold or regular green coolant, and says to put in what was in it at the factory. Not being a mind reader, I called the local dealership to see what was with this. They gave me two different answers after transferring me all over the place (they never have been very bright at this place), and settled on Gold coolant. Problem is, the overflow tank has a graphic of a tilted-over bottle with gold liquid in it with a big slash through it. I figured I'd follow wiswind's advice and go with a Xerex G-05 coolant, but now I have no idea at all what to put in. If it's green, I should have changed it at 60K, but if it's Gold, I can wait until 100K. I just topped off with 50/50 green; hope that was right!

Hopefully some knowledgable soul will read this and take pity on us newbies!

As far as the spark plugs I went under the van and flew blind only going by feel as it was ok. Others have pulled the cowl off by the windshield and had success still not able to see to much but mainly feel. As for the coolant I just pull my lower bottle hose about every oil change now and run Advanced all makes all models formula. The first time I drained the radiator. The easy way is to take to dealer or local shop the have the flush system. At least on the van do to the long heater hoses to the rear and making sure you get all air out of the lines can be a pain.

Found some pertinent links:
http://www.automotiveforums.com/vbulletin/t651645.html
http://www.automotiveforums.com/vbulletin/t461226.html
http://www.automotiveforums.com/vbulletin/t549248.html
http://www.automotiveforums.com/vbulletin/t346203.html
http://www.automotiveforums.com/vbulletin/t489207.html
http://www.cartrackers.com/Forums/live/fordwindstar/1983.html
http://s24.photobucket.com/albums/c30/ddibiase/Windstar%20Project/?action=view&current=06073001.jpg- this is the cowl removed so you can get behind the engine

Hope this helps some. Still searching on the radiator flush and reading...

Embalmer
As others have mentioned to replace the plugs and plug wires is a pain. However if you plan on removing the upper intake manifold its not so bad. Remove the cowl though its much easier. Remove one wire at a time. Watch how there routed and start with the one that is furthest down in the clips that hold the wires. Buy Factory original as the lengths will be a better fit and you can get them for a decent price on TeamFord.com. They are very helpful if you need to call and get additional info. Plugs I would reccomend the Autolite platinumsearch or look at Wiswind pictures I believe he has a picture though his van is a 96 so check with an auto supply or dealer. I would replace the thermostat and gasket, the serpentine belt, radiator hoses. Check for noise from the idler pulley and tensioner both seem to go right about your mileage. If you decide to do the intake search for other reccomendations before ordering anything. Its nice to have everything ahead of time so you dont have to keep running for parts. Any question post back.

Well, I'm posting my results from the latest maintenance-athon. I did the front plugs and wires last Thursday with no problems. Then, I realized the work involved to get at the back ones and I decided to wait for tonight and do the EGR cleaning, rear plugs and wires and a trans flush. I did the flush first - no issues with that. It's a piece of cake to just drop the lower line and pump the old out, add more, flush, reconnect, top off, DONE. Next, I removed the wipers and cowls. Then, I removed the upper and lower intakes, cleaned them out, cleaned the EGR ports, sprayed the secondary throttles, installed my new gaskets. I then did the rear plugs and wires, bolted the intake back up, reconnected everything and fired her up! She runs a lot quieter and smoother now with some noticeable acceleration gains. Maybe she'll keep up with her stablemate!:naughty:

http://i77.photobucket.com/albums/j56/faxisis/061007006.jpg

http://i77.photobucket.com/albums/j56/faxisis/102_0205.jpg