Cylinder head replacement

[pvmarcon]

Can anyone tell me how difficult it is to change the front bank cylinder head on a 95 3.8? My mechanic tells me he suspects a bad exhaust valve on #4 cylinder and he says it would cost $1350 to fix. I can get a reman head for $150 and a gasket for $45 and am somewhat capable. Where can I get instructions and torque specs to tackle this job?Thanks

[Vairpilot]

Go get a Haynes or Chilton manual for the Windstar, or an Alldata subscription. I actually have the Alldata and a Haynes manual for mine. Alldata includes all the service bulletins which are nice to have, as well as the torque sequences and values you are looking for. The Haynes/Chilton manuals will have disassembly/assembly sequences that are easy to follow. Replacing the head is fairly easy, just make sure the replacement head is straight, use a metal straightedge and feeler guages to check it. The tolerance values for it will be in the previously mentioned reference materials. I've done heads on some GM's in the past, this one was no worse than any of those, I'd set aside a weekend for it if it is your first time. Make sure to get an upper gasket set, you'll want to replace the lower intake manifold gaskets and any others that are old or damaged. Get a new set of head bolts, should be 4 long and 4 short in a package. Use an accurate torque wrench too. If I were you, I'd probably pull the other head while you are at it, wouldn't be much work once you get down to the heads. The 95's have a reputation for bad head gaskets, so you might as well do it now while it is torn down.

[wiswind]

As mentioned, you will need new head bolts and new lower intake manifold gaskets as these are NOT reusable.

AutoZone has a lot of information on their website under "vehicle specific repair...." as well as a link to the alldatadiy website.
I seem to remember that the free information includes the torque values and the pattern that the bolts are to be tightened.
Take note of the difference in INCH pounds and FT pounds in the specifications.....some people have missed this.....and a bolt that calls for 25 in/lbs will not be happy with 25 ft/lbs!!

From reading the TSB's that FORD has issued, you need to be aware of a couple of things.

First, do NOT use any metal tooling, including razer blades to remove any of the material that is stuck on the head or lower intake manifold gasket mating surfaces.
They say to use ONLY nylon or wood tooling.
Metal tooling, such as razer blades, will scratch the soft, aluminium surfaces and leave grooves.....which will lead to wicking and then gasket failure.
You may need to use some solvent to soften up the material that is on the gasket seating surfaces.
You do want to clean all dirt, oil, etc from the gasket seating surfaces.

2. You "dry fit" the head gaskets and the lower intake manifold gaskets.
This means that NO other sealers or aids are to be used......as they will lead to failure of the gasket.
The gaskets are designed to seal on their own....and other stuff will prevent this.
So use a solvent to clean ALL oil residue from the mating surfaces, and dry fit these gaskets.

Also, it would be best to get the gaskets from FORD, so as to get the latest improvements.

[zman327]

I just completed head gasket replacement on my 1995 3.8 Windstar. Some issues that I had were: Chilton manual has specs for 1996 & up. The 1995 Windstar has the Ford Taurus motor in it so the intake manifold is different from any other years of Windstars. I torqued the intake bolts to 20 ft lbs using teflon sealant on the threads. I planed my heads to correct the warp ($75). Be sure to place the head gasket on the correct way. Front is labeled on the head gasket and it goes toward the water pump. One gasket will be installed upside down but the larger cooling holes line up with the #1 & #4 cylinders to aid circulation. Tighten the new head bolts according to the book & check all pushrods for wear ( I had a cracked on). Front bank is the easiest but the rear bank isn't that bad. Good luck & expect about a $500 cost. I used Felpro head gasket kit for $90 vs the OEM Ford head gaskets only for $265. Who do you think makes the gaskets for Ford?