96 Windstar Loud Engine Knocking

Hi everyone,

My daily driver, '96 Windstar with the 3.8L is knocking really loud. At first, it only happed around 2500rpms, but now it's gotten very bad. It knocks really loud from 2000-3000rpms. It happens when I'm on the gas or off.

Does anyone know what it is? It definately sounds like it's coming from the bottom, maybe the right side. It's got 157,000kms on it and we've had it since Day 1, and done oil changes every 5000kms.

Thanks in advance.

- Jon

Sounds like a rod bearing or main bearing gave out on you. It's motor yankin' time.

does it sound like this?? (now grant it this is a cavalier but just to give you an example) http://www.youtube.com/watch?v=uU2w89MFlKY

I wonder if it's intake gasket related? Seen a lot of 3.8's die this way...

does it sound like this?? (now grant it this is a cavalier but just to give you an example) http://www.youtube.com/watch?v=uU2w89MFlKY

Sounds EXACTLY like that! What is the problem and what can be done about it? Thanks!

Sounds EXACTLY like that! What is the problem and what can be done about it? Thanks!well in my case I was told that was a spun bearing and that ment 2 options,

A)rebuild the engine
B)new engine

well in my case I was told that was a spun bearing and that ment 2 options,

A)rebuild the engine
B)new engine
Not what I wanted to hear :( lol, thanks though...

I dunno if I should put a new engine in it or just replace it with a '98-00 Explorer.

IMO I would replace it with the explorer. Do you really have a need for the minivan??

IMO I would replace it with the explorer. Do you really have a need for the minivan??
Not really, but I've had it since day 1 so I know the history of it. I'm afraid of buying a used car and then it'll end up having even more problems.

Yeah thats the problem of buying a used car. The only other thing I could suggest then is buy something brand new or rebuild/swap a new engine into you windstar.

Yeah thats the problem of buying a used car. The only other thing I could suggest then is buy something brand new or rebuild/swap a new engine into you windstar.
Can't really afford something new since I have a CTS-V as a weekend car... Looking at a rebuilt engine I guess. :(

CTS-V you say huh :naughty: how is that thing???

A blast. It's my baby. So much fun. :)

Man I can only imagine how much fun that thing would be. Do you have any pics of it??

A caddy? Don't they hand assemble every engine in the V series?

A caddy? Don't they hand assemble every engine in the V series?:dunno: wouldnt surprise me though.

Man I can only imagine how much fun that thing would be. Do you have any pics of it??

http://www.jon04ctsv.com/Detailed/IMG_6582.jpg
http://www.jon04ctsv.com/Detailed/IMG_6604.jpg
http://www.jon04ctsv.com/Detailed/IMG_6571.jpg
http://www.jon04ctsv.com/Detailed/IMG_6616.jpg
http://www.jon04ctsv.com/Detailed/IMG_6643.jpg
http://www.jon04ctsv.com/Detailed/IMG_6630.jpg
http://www.jon04ctsv.com/Detailed/IMG_6648.jpg
http://www.jon04ctsv.com/Detailed/IMG_6651.jpg
http://www.jon04ctsv.com/Detailed/IMG_6652.jpg
http://www.jon04ctsv.com/Detailed/IMG_6660.jpg
http://www.jon04ctsv.com/Detailed/IMG_6655.jpg

I'm in love with that thing man!!!!! :boink:

No doubt, that is a b-e-a-utiful car!! I just looked it up...All the V-series DO have hand-built engines. Who would've though..we spend all these years trying to make machines to assemble engines, and yet they're no match for a set of hands...

Well....the explorer will give you same or less fuel economy, but has much less room inside.
The windstar is much more usable....although the explorer may be better for towing, if you tow anything heavy.
I looked into an explorer...but decided to buy the windstar, as, if I was going to go from a small car that got great fuel economy to something like that.....I wanted to get more room for my money.
Of course, I had to put up with my friends calling me a soccer mom......
The explorer is more in style....but I gave up on style LONG ago......

The '96 windstar is better on head gaskets than people say.....the '95 was bad for head gaskets......
However the '96 is still a problem for lower intake manifold gaskets....which can be misdiagnosed as a head gasket issue.....and you have to replace the lower intake manifold gaskets when you do the head gaskets.
The other coolant leak for the '96 is the front cover gasket, also called "timing cover" gasket. The gasket is cheap, but the labor is MAJOR for the front cover gasket.
I would ONLY use FORD / Motorcraft replacement gaskets as they have been updated.....as in improved....so as to prevent the failure.
MANY vehicles nowadays have problems with the lower intake manifold gaskets.

OK....reason for my going on about those 2 gaskets........they cause your antifreeze to leak into the engine oil......which causes exactly the problem you are having.
So.....if you have the engine repaired.....you want to have those gaskets replaced.
I have kept the front cover gasket sealed with Bar's Stop Leak....but I got it very early in the game.
It was a bandaid fix for the lower intake manifold gasket...and it still had leakage......so I now have new lower intake manifold gaskets.

I STRONGLY recommed that people with these older windstars get their oil tested. www.blackstone-labs.com is a good place.
They will send you a sample kit and mailer for FREE.
It is cheap to get your oil tested......and this is the ONLY way to detect coolant in the oil.
The old method of looking for "milky substance" on the inside of the oil fill cap, or looking for it settling to the bottom of the oil pan.....or milky oil....etc......are WAY TOO LATE.
It will do much damage LONG before the leak is bad enough to be visible to the eye.
If you are having a slow loss of coolant, you likely have the leakage I am talking about.

Who would've though..we spend all these years trying to make machines to assemble engines, and yet they're no match for a set of hands...Aint that the truth nothing beats a good set of hands :thumbsup:

Well, I was on my way, taking it to a shop today, to have it looked at and it died. Wouldn't start back up at first, but then it fired up again. Once I put it in gear though, it died again. Damn it. :(

Well, I was on my way, taking it to a shop today, to have it looked at and it died. Wouldn't start back up at first, but then it fired up again. Once I put it in gear though, it died again. Damn it. :(Well my friend I think its time for that new engine in there lol

By all means don't drive it any more. If it's about to throw a rod and DOES throw a rod, you might be looking at replacing the block as well. If you shut it down and rebuild it before then you can probably save the block 99% of the time.

Just depends where the pieces decide to exit the engine at...through the side of the block, through the oilpan, etc etc.

If you decide to go with a "previously owned" engine, say from a Junk yard.....I would ONLY use one from the same year.
Also, before the engine is put into your vehicle......I would have the front cover gasket replaced, and the lower intake manifold gasket replaced.
Make sure that ONLY FORD / Motorcraft gaskets are used, as they have been updated (improved).
The lower intake manifold gasket can be done with the engine in the vehicle, however, the front cover gasket, a cheap part (under $20), is very labor intensive to do with the engine in the vehicle.

If you drive it 'til it throws a rod, those torque converter bolts will be SUPER hard to remove. I've had to cut crankshafts in half to remove them before if the engine seized..