Oil pouring into exh. need rec. on long block supplier

96 Windstar 3.8 SE 180k

Pulling out of the driveway today with a cold engine I got about 30 ft when there was a quick odd underhood sound like pressure releasing -- zzzzppphhhttt then an immediate clack clack clack and it started running rough. I quickly pulled over and shut it down and straight oil was dripping out of the catalytic converter horizontal center seam -- it quickly pumped about 1/4 quart of pure, newly changed oil into the exhaust system!

The clack clack clack sounded like it was coming from the piston closest to passenger seat. Loud enough to be piston contacting a valve but not a bottom end clunk. One Ford mechanic thought that a hole in the piston would push mega oil out into the exhaust...

There is also a sprayed oil pattern over the engine compartment that looks like it came from about the central intake mani on over towards the drivers side.

Just before this happened I noticed it was losing coolant -- no major leaks or white exhaust smoke or water in the oil but a slightly oily coolant and a little coolant around the intake gaskets which (I just bought the replacement gaskets!) No oil use.

I know it's tear down time but I wonder what folks think would push oil out like that? I was thinking that a cylinder full of coolant might blow the head gasket which doesn't seem to account for the clack clack noise...

Just got off the phone with NECO engines, $3699. installed(!) 5 yr. warr. $350 core if mine NG. 1 week turnaround...

Anyone have a recommended long block supplier or rebuilder in the New Haven, CT area?

Thanks.

Hey Shannon-

Sorry to hear of your problem. I too live in Connecticut and have a '99 3.8L with 150K. I have begun researching rebuilt 3.8L engines - and while I'm no expert - the price from NECO seems outrageous. Right now on ebay - you can get a rebuilt engine delivered to your door for about $1500.00. I'm guessing at worst - you'd have to pay somebody $1000.00 for the installation. I expect that with a few serious days of shopping around - you'd be able to do better.

My guess on your problem is that you may have dropped a valve. Maybe a broken valve keeper is the culprit. I'm thinking a broken exhaust valve would explain all of your symptoms.

If it were me - I would probably remove the cowl - remove the rear valve cover and see what's up. If you do see the loose springs - maybe your best bet would be to pop off the head and see if it may be salvaged.

Good Luck !! -- Please keep us informed

Your situation is well beyond my skill level.
However, another remanufactured engine company (though not cheap) is Jasper.
They have a website, and I know that they carry the motor for the 1996, but don't recall the price.
They have a option for you to enter your zip code and find a installer near you.

Another source (again not cheap) is FORD.

I would check these 2 out and see what the prices are.......as these are supposed to be "top shelf" quality.

I am sure that there are local shops in your area that you could find in your yellow pages or internet search.
However, it is best to know how much a top quality unit will cost......so you can decide if the next level down is really saving you enough money to be worth it.

This is a link to some history information on the FORD 3.8L motor that another member posted a while back.
TAKE NOTE that the FRONT WHEEL DRIVE 3.8L motor is different from the rear wheel drive.
http://www.babcox.com/editorial/ar/ar90134.htm