98 Windstar - It's Dead !

Hello
I found your website on the Internet after an exhausting search regarding a problem that has turned into a nightmare with my recently purchased 98 Ford Windstar 3.8. I bought the vehicle after many recommendations from fellow Police Officer’s that have purchased vans in the past from this particular dealer. The van in question was driven by a lady who ran a daycare centre and was told that it was well maintained. What I found out was just the opposite. One day driving home from work pulling away from a stop sign, I pressed on the gas and it bogged down. When I let my foot off the gas it idled normally but felt like it was missing and getting what I was told later backfiring under the hood. It would start but would idle very rough then just die. When cold it would start easily but when it reaches top operating temperature it gets very rough after 20-30 minutes running or idling. If you put your foot on the gas it flutters and quits. I recently have replaced the Gas Filter, Idle Air Controller ( after Ford told me this was the problem ) Gas Pressure Regulator, Throttle Positioning Sensor, Spark Plugs ( Bosch Platinum’s ) after I found the original plugs were in the van 145,000 kmhs, etc. etc. I had one mechanic tell me that the Catalytic Converters were plugged so he cut those off only to find out that this was not the problem either. After changing the plugs today it will run or idle but when you ‘punch the gas’ it misses and once again it will start to run very rough but will smooth out only if you take your foot off the gas. I had the chance to take it around the block but when you apply the gas going up hill it starts to chug and miss. We have checked the vacuum lines etc but can’t seem to find the problem. The codes we have retrieved were TPS and another code telling us that it was running lean. I believe it was 1071 1072.
What I did hear tonight was a slight hissing noise coming from the area in the front dash near the heater and radio that sounds to be that of letting air out of a bicycle tire. This is a new one. A friend who is a mechanic is stumped. Another local mechanic told me that it could be the Ignition Module since when I hold the gas pedal at 1500 RPM’s and the idle drops back to around 900 RPM’s, this could be problem. He still has not arrived with his code checker as I’ve been told he has been very busy doing his house calls. Could this be the problem? Your reply is awaited with interest… I really enjoy this forum for the problems experienced and still investigating.

A Frustrated Ford Owner

Finding and fixing those air leaks should be high on your agenda ... and may be your only real problem.

let the van run for a while and look at the gas tank - I have seen plugged evap canisters on windstars - if the cans are plugged it will build a large amout of vacume in the tank and actualy suck the bottom of the tank right off the straps that hold it in

I recently recovered from a similar problem with a '97 3.8l Windstar. My misfire was on cylinder 2 with a lean condition in bank 1. I suspected an EGR port problem, which is common for these engines-- all but one or two EGR ports clogs up and the excess gass causes a misfire in the cylinder(s) with still-open port(s). I also suspected a bad injector sticking open and flooding the cylinder.

Your problem could be that but it sounds more like a vaccum leak. There is on vacuum hose that powers the ac/heat inside the vehicle, disconnect that in the engine compartment and plug it off and see if that helps.

In the course of investigation of my problem, I found I had a leaking head gasket and spent the last two months doing repairs. I have written a whole dialog on the entire process with my errors and lessons learned and everything here:

http://www.automotiveforums.com/vbulletin/showthread.php?t=310897

If you hear a hissing from inside your van...as you describe.... The heater controls are VACUUM controlled. Any leak here....is air getting into your intake manifold that your computer does NOT know about. Solve the hiss in your dash FIRST.
Are all of your heater / air controls working correctly?
I understand (but do not have personal experience) that the heater selector door and the "blend" door " are hard to get at....so set aside a lot of time.....check autozone's website for free repair information.....if you do not have a good source of information already. For some EGR information....I have some pictures posted that may help you out there.....but....do this after taking care of the leak that you have in your dash....

Pictures at.... http://community.webshots.com/album/201931518cScpNK

Well it sounds like you are all right on your diagnosis. I went and started the van and when I turn on the heater the ol 3.8 starts to cough and hiccup and just dies. As soon as I turn on the power to start the blower all H brakes loose. Where do I start to find what Vacuum hose under the hood.? I can hear air blowing from somewhere but can't pinpoint the area. It's one of those things that drives you nuts when you can hear it but can't find it. I'm starting to think that this was done deliberately when one mechanic was just out to make a buck. On the rear firewall in the middle there is a valve with hoses but next to it there is another piece of or extension that looks to have or is supposed to have a hose connected to it but is missing. You can't reach it, or see where it supposed to go. I can hear air blowing under the hood when the engine is running and also in the dash in the area of the radio and heater controls. Would this be coming from the firewall ?? I need a break............this is my first Ford and never expected anything like this when they make it hard for the average person to any kind of work. Stay in touch and thanks.....

To get to the rear of the engine for a good look, you may find it necessary to remove the wiper arms and then the plastic cowling. The cowling was made to be removable....the upper piece is held in place with clips, the lower with a dozen, or so, small screws. Once you do the removal the first time, it will be easier thereafter.

Pull the cowling as 12Ounce describes. Watch for the windshield wiper fluid hose the runs from the upper cowling through a grommet in the lower housing. It is a rigid plastic tube and will break very quickly if you aren't watching for it.

On the firewall to your left there is a vacuum line (red on my '97) that plugs into a device and a hose leads from that device into the cabin. That is your accessory vacuum for your ac/heater.

I believe the component in the middle you were describing is the Vapor Canister Purge control solenoid (or Vapor Management Valve, depending on who you talk to), it has two large hoses and a smaller yellow vacuum hose and an electrical connector.

Interesting thread. Vac noises definitely worth looking into. If problem persists, do these cars have a Mass Air Flow Sensor? I had a VW Golf with a bad connector at the MAF sensor which acted just like that.