engine quit running on interstate

[jasper2222]

I just purchased a 96 3.8 liter Windstar with 77,000 miles. I was driving it home from Penn. Went about 800 miles, no problems. I then stopped and got fuel at a large Oasis Truck Stop. Pulled through to the Restaruant. When I returned to the car and started it, it ran rough. I gave it some gas, turned off the A/C., and it started running fine. I proceeded another 150 miles and then, while going 70mph on the interstate, the engine just died. I had electric. Tried to restart it, the engine tried to start but ran real rough and then died right away. I let it sit for about 15 min. and then tried again and it ran fine. I made it about another 1/4 mile before it quit again. I then had it towed. We were able to drive up on the tow truck, no problem. I suspected a fuel filter. I took it to the dealer and they say the engine is fine, but they suspect a transmission problem. I just can not relate that a transmission problem is causing these symtoms. Any ideas. The car has been sitting a great deal for the last 3 years. About 3000 miles in 3 years.

[wiswind]

Are you having to add cooant?
If so, it could be a leaking lower intake manifold gasket.
Mine DID tend to cause temporary rough running on startup right after a short stop at a freeway rest area whenmy lower intake manifold gaskets were leaking slightly.
But, in my case, it always cleared right up within a minute.
Good news is, unless the engine has been seriously overheated, the head gasktets on the post 1995 Windstars are pretty reliable, and not likely to be a problem.
The Lower Intake manifold gasket leak is easy to mis-diagnose as a head gasket leak, as coolant leaks into the intake manifold, and is drawn into the cylinders.
The new lower intake manifold gaskets are improved, to prevent the issues that caused them to fail, so it would be a 1 time repair.
I have pictures of various repair projects, including lower intake manifold gaskets, in the pictures that the link in my signature takes you to.

If not, as you don't mention a Check Engine Light (CEL), it could be a fuel delivery issue.
The PCM does not monitor fuel pressure or fuel flow, so there will not be any CEL or codes for that directly.
Fuel filter was a good idea....and you should verify that your's is relatively new, as it is one of the cheaper solutions, and is routine maintenance anyhow.

Another issue could be the Constant Control Relay Module (CCRM).
On the 1996, the CCRM is a box that contains a number of relays, including he fuel pump relay.
TSB # 97-2-12 addresses a no start condition after a "heat soak" in below freezing weather.
Your drive on the turnpike, stoping for gas, and trying to start again is just the condition they mention.
Moisture would get into the fuel pump relay, and cause the fuel pump to not run, after the vehicle has been driven for a while and then shut down for about 15 minutes.
The solution was to replace the CCRM unit with a new one that had better sealed relays.
I have not seen posts here that indicated this problem, but I thought that I would pass along the TSB information.

It might be worth having the fuel pressure at the fuel rail checked out.
Your fuel pump could be getting weak.
Worse yet would be a intermittent problem with the fuel pump, works fine when you are checking, acts up when you are out on the road.

I would expect you to have a CEL if the EGR system were acting up (including clogged EGR ports).
It could be a EGR flow code ( Too much, or too little flow) or a misfire code on cylinder #3 or 4.
A temporary thing that you can do to determine if EGR is the problem is to remove and plug the vaccum line that goes to the top of the EGR valve, and go for a drive.
If the problem clears up, it would indicate a EGR problem.
Doing this SHOULD cause the CEL to come on with a stored code indicating too little EGR flow, as you have disabled the EGR valve from opening.
It is possible that the EGR valve could stick open, but it is not common for the EGR valve itself to be a problem on the Windstar.
EGR problems are usually the Delta Pressure FEedback (DPFE) sensor or clogged EGR ports in the lower intake manifold.

As this vehicle has been sittng, intermitent fuel pump is more likely.
Moisture in the fuel system?
I would also change ALL the fluids, and run a good 3 tanks of gasoline, each treated with a can of Berryman's B-12 Chemtool Fuel system cleaner.
It is one of the less expensive cleaners, and it DOES work, when I did not get issues resolved with other, more expensive cleaners.
From sitting, it is possible that your whole problem is stale fuel, varnish deposits, or moisture
I would include the coolant, Power Steering (use ATF), Transmission Fluid (Mercon V ATF), engine oil, and a good bleed of brake fluid at each wheel.

[jasper2222]

It was the fuel filter.

[tomj76]

Did the dealership offer you a position in their service department?