Thanks Alot 12Ounce,
Now that all makes sense. Time to figure out a plan of attack!
Would you suggest doing another complete flush and trying something like "Bars Heavy Duty Stop Leak" or "Thermagasket"? If so what product would you recomend as it would only need to be a temporary fix (2-4) weeks untill I can tear it apart and fix?
From your thoughts and previous reading in the Windstar forum it does sound almost 100% like the lower intake/crossover line. So I am ordering a kit from Blackstone Labs
http://www.blackstone-labs.com to have my oil tested for any coolant, should have the results back in time to have the money to order all the parts from Ford.
What are your suggestions as far as the Timing Chain Cover leakage? I keep checking it and have not seen any more leakage or bubbles coming from around it. Should I replace that too (just gasket or cover and gasket)? Or could I use something like Bars? From what I've read, this is a common problem with the 3.8L 98's and older and a pain to get at while engine still in van.
Also, while I now have an excuse to take apart the top of the engine, I can get all my routine cleaning done! Would you suggest that while I am already going to be putting in the labor to get at the lower intake manifold gaskets and replacing that crossover coolant line should I be prepared to remove the lower intake and replace the Head Gaskets? and if so, how much more time and effort would that involve? Really not looking forward to doing that job! What about the water pump? Anything else I should be looking at replacing?
I would like to have a great running and reliable Windstar for personal (carring around 4 kids+) and work (delivering newspapers 365days a yr) that will last me at least another 100,000miles but I also don't want to keep throwing my time and money into it just to encounter another big problem that needs to be addressed (knock on lots of wood very quietly) like the tranny or engines bottom end.