1997 3.8 intermittent breakdowns
stevenkp89
03-02-2004, 09:19 PM
New to this forum, but I could really use this groups help.
I have a modified 1997 Ford Windstar 3.8 with 55,000 miles. This is a wheelchair converted van with an 8” drop floor (for head room) The van is otherwise mechanically unaltered with the exception of re-routing the exhaust system to accommodate the drop floor.
My problem is intermittent, but on-going and unpredictable. On 3 separate occasions in the past 18 months the van while cruising down the highway at 65 mph starts to sputter and loses power or even stalls. Pull over to the shoulder and attempt to restart, and it will either sputter and die, or not start. The first two times I was towed home, BIG problem since I am in a wheelchair, AAA takes the car but not me. The next day the car started fine, and I brought it to a trusted mechanic who could find nothing wrong other than a misfire code. The third time I waited 30 min and the car restarted and ran fine for the rest of the trip.
What I know so far:
In all cases:
I had plenty of fuel (fuel filter changed after first time, plugs and wires changed also)
Driving speed was 65-70 mph on flat straight highway.
Breakdown was always 1 hr into a 2 hr trip.
Weather was always Dry (thank God)
Temperature was cool to moderate, no extremes on either end.
All fluid levels OK
Battery OK
Engine temp Normal
Engine would sputter quickly about 2 or 3 times about 4-5 miles before it died.
Other may be related item:
I mentioned the drop floor earlier, because speed bumps in parking lots are HELL!!
Even at the slowest crawl my exhaust system bangs at the front (just behind the front wheels) The Meineke guy loves me because I go through 2-3 exhaust systems a year.
In ALL cases, the exhaust leaks have been pretty bad when the breakdown occurs.
My main questions:
1 Could this exhaust leak be the cause of my breakdown either by:
a. Throwing off the O2 sensor and the engine mixture or
b. Heating up a component by throwing hot exhaust gases on it causing the computer to go funky.
2 What can I do to pinpoint a source of this problem?
After the last breakdown two weeks ago I purchased the AutoTap diagnostic tool that will connect between my laptop and the OBD II port. I also have the enhanced software so I can access all 150+ parameters. I have also fixed the exhaust AGAIN.
So far I can find nothing wrong, but would like to be proactive about this. I have good diagnostic skills, and a strong understanding of how these things should work, but I am utterly stumped.
Please any help would be appreciated. I put myself in your collective good hands.
Thanks,
Steven
I have a modified 1997 Ford Windstar 3.8 with 55,000 miles. This is a wheelchair converted van with an 8” drop floor (for head room) The van is otherwise mechanically unaltered with the exception of re-routing the exhaust system to accommodate the drop floor.
My problem is intermittent, but on-going and unpredictable. On 3 separate occasions in the past 18 months the van while cruising down the highway at 65 mph starts to sputter and loses power or even stalls. Pull over to the shoulder and attempt to restart, and it will either sputter and die, or not start. The first two times I was towed home, BIG problem since I am in a wheelchair, AAA takes the car but not me. The next day the car started fine, and I brought it to a trusted mechanic who could find nothing wrong other than a misfire code. The third time I waited 30 min and the car restarted and ran fine for the rest of the trip.
What I know so far:
In all cases:
I had plenty of fuel (fuel filter changed after first time, plugs and wires changed also)
Driving speed was 65-70 mph on flat straight highway.
Breakdown was always 1 hr into a 2 hr trip.
Weather was always Dry (thank God)
Temperature was cool to moderate, no extremes on either end.
All fluid levels OK
Battery OK
Engine temp Normal
Engine would sputter quickly about 2 or 3 times about 4-5 miles before it died.
Other may be related item:
I mentioned the drop floor earlier, because speed bumps in parking lots are HELL!!
Even at the slowest crawl my exhaust system bangs at the front (just behind the front wheels) The Meineke guy loves me because I go through 2-3 exhaust systems a year.
In ALL cases, the exhaust leaks have been pretty bad when the breakdown occurs.
My main questions:
1 Could this exhaust leak be the cause of my breakdown either by:
a. Throwing off the O2 sensor and the engine mixture or
b. Heating up a component by throwing hot exhaust gases on it causing the computer to go funky.
2 What can I do to pinpoint a source of this problem?
After the last breakdown two weeks ago I purchased the AutoTap diagnostic tool that will connect between my laptop and the OBD II port. I also have the enhanced software so I can access all 150+ parameters. I have also fixed the exhaust AGAIN.
So far I can find nothing wrong, but would like to be proactive about this. I have good diagnostic skills, and a strong understanding of how these things should work, but I am utterly stumped.
Please any help would be appreciated. I put myself in your collective good hands.
Thanks,
Steven
rodeo02
03-02-2004, 10:08 PM
Steven- as you've already found out, it's difficult (and expensive) to troubleshoot unless an OBDII code locks in, or the van wont restart at all. It sounds like you are on the right track with the hardware & software you purchased- you've got the deluxe setup at your disposal :)
With the symptoms you describe, I would suspect a crank or cam position sensor issue (I'm not sure which the 1997 3.8L has). When these go out, you loose signal to your ignition coil(s) and loose all spark . O2 sensor(s), EGR, or mass air flow sensor issues USUALLY do not result in a complete stall & no restart condition. Do you get a gasoline smell while attempting a restart when this happens? (indicative of a no spark, but plenty of gas condition). You may be on the right track with something (sensor) getting hot after an hour at hywy speeds, causing it to malfunction.
G/luck
Joel
With the symptoms you describe, I would suspect a crank or cam position sensor issue (I'm not sure which the 1997 3.8L has). When these go out, you loose signal to your ignition coil(s) and loose all spark . O2 sensor(s), EGR, or mass air flow sensor issues USUALLY do not result in a complete stall & no restart condition. Do you get a gasoline smell while attempting a restart when this happens? (indicative of a no spark, but plenty of gas condition). You may be on the right track with something (sensor) getting hot after an hour at hywy speeds, causing it to malfunction.
G/luck
Joel
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