OK. I've searched through and read all the relavent posts in the Windstar forums. I've also searched for as much available info on 3.8 rebuilding. Anyone out there have any experience doing it themselves? If so, is there a kit or parts supplier you'd reccomend? I'm not looking to get a "speed" kit, just good, solid parts. Thanks in advance!

I'm in the process of rebuilding a '99 3.8. 218 kmiles. I just bought things piecemeal ... as I was convinced they were needed. Bought the upper gasket set from AutoZone (Felpro). Bought the lower from Ford ... as I've had some issues with crankseals from Felpro. Just honed the cyls as oversize pistons weren't needed. The crank did not require machining.

The heads/valves done by Dover. Had the block honed and surfaced by Chastain Engines. New rings, bearings, seals, etc. The oil pump was opened and inspected ... looked OK. A lot of decarboning labor throughout (me). The short block is assembled and installed in vehicle. Hopefully the oil pan, heads and upper intake goes on tomorrow.

I bought a lot of new rubber. Engine, new rad, reman tranny, reman steering ... gonna set me back about $4K ... maybe slightly plus.

Best thing if you are going to do it your self. Check with a local machine shop. They will be happy to order what ever parts you need as far as internal. Even if you are going to keep it stock. I would put out for a basic port and polish of the heads and a valve job. Less carbon builds up after this is done. Thats as long as you still keep the oil changed in it. Some times after a rebuild the PCM may need to be updated and tuned since some of air flow in the engine may have changed. Mainly if the block needs to be bored. More compression added more fine tuning of the PCM. I see a lot of times problems occur after a rebuild on later model cars. So if a only a block hone is needed, thats the best way to go..