Lower Intake Gaskets 96 3.8

[96wWindstar180K]

kevink1955
Now you have me wondering if I did'nt have the 4mm set. I dont have the packaging any more but the part # is correct. Did the thinner set assemble easier? or did you still have to play with the manifold bolts?

[kevink1955]

Originally Posted by 96wWindstar180K

kevink1955
Now you have me wondering if I did'nt have the 4mm set. I dont have the packaging any more but the part # is correct. Did the thinner set assemble easier? or did you still have to play with the manifold bolts?

You said in another post that the kit you used

All data list them as right side XU2Z9439CA left side as XU2Z9439DA

If that is the correct number they are 3mm gaskets, I still had to fight a little to get the manifold in place. The TSB from the ford truck site says you have to catch 2 of the center bolts to draw the manifold down so you can catch the rest of the bolts.

I think you have the correct gaskets, as I said before the 4mm gaskets held the manifold up did not crush the end seals so there would have been an oil leak if I left it as is.

I do not know if it helps but the 3mm gaskets I got had copper color spacers at the bolt holes and the 4mm set had silver/gray spacers. Looking at Wiswinds pictures you can see what I am talking about as well as the 3mm part numbers.

[kevink1955]

Update on the check engine light after the gasket replacment

Went in to our truck shop to get the codes read, they where using the scanner to solve a driveabilty problem on an ambulance so I could not use it.

I disconnected the battery cable to clear it and went on to do some errands, I drove about 45 mixed traffic/hwy miles before I got back home and the check engine light has NOT come back.

I think it's cured, it seems to be runing better than before but that may be cause I got used to the wifes Escort in the last few days.

[wiswind]

When you "clear" the codes, the PCM has to re-learn the "drivability" information, which includes fuel trim information and the ideal transmission shift points.
So don't worry if you notice a few minor shift and performance issues at first.

Also, over the next few days, check the coolant level as it may take a few days to "burp" all the air out of the system.

[s1120]

Well I am doing my gaskets this weekend!

I had had a cyl 4 missfire, and needed to change the plugs and wires anyway[110k on OE stuff] so figured sence I was in there, I would takel the intake. It was pretty crudded up. Cleaned it well,about half the egr jets were more then half plugged.[number four was clear as could be. I bet it was getting all, and thus the missfire] Guess my only fear is that I remember where all the wires went.


And thanks for who ever posted about removing the cowel. That is making it a LOT easer to work on!!!!!!!

[s1120]

Finished the job today!!! Runs awsome!!! Still need some miles on it to get the PCM to relearn, but other then that good.

I tell you... I dont know what book time is on that job, but I should did not make any money today. Well maybe concerding I did the plugs, and wires, cleaned the TB, and IAC, and replaced the EGR tube, and fitting on the manafold.

Thanks for all the tips guys!!!!

[96wWindstar180K]

s1120
How did your manifold line up when you put it back? Were the bolts hard to start and line up? Just wondering I also have a 96 3.8 and did the gaskets and my manifold took alot to line up. I wondered if I had the right gaskets.

Glad everything worked out for you.

[s1120]

Originally Posted by 96wWindstar180K

s1120
How did your manifold line up when you put it back? Were the bolts hard to start and line up? Just wondering I also have a 96 3.8 and did the gaskets and my manifold took alot to line up. I wondered if I had the right gaskets.

Glad everything worked out for you.

Took a little playing around, but not much. The bolts at first did not line up, so I Made shure I could see the holes, then as I started them, I leaned on the intake to push it down a bit. Once they started they went right in and snugged it right up.

[96wWindstar180K]

s1120
Thats how mine was I guess. It came off easier then it went on. You have not started getting any hesitaion problem have you? I dont know if mine is related to the gasket change or something else. Thanks

[kevink1955]

Did mine a little over 2 weeks ago and it's also runing great. if you remember I was orignily given the wrong gaskets by the dealer.

96W -- After fitting it up with the wrong gaskets I am convinced that it would never have sealed properly, dont worry about yours. If it's runing and not loosing coolant or oil your fine. Now go after the hesiation problem, have you looked at the Throtle Position Sensor (TPS) If it has a dead spot the ECM will not know that you moved the throtle and cannot adjust fuel properly.

[s1120]

Originally Posted by 96wWindstar180K

s1120
Thats how mine was I guess. It came off easier then it went on. You have not started getting any hesitaion problem have you? I dont know if mine is related to the gasket change or something else. Thanks

How long ago have you done it?? My had a wicked Hesitaion right after I did it, but with about 200miles on it the last two days, it has cleared up. Needed to give the computer time to learn.

[s1120]

Well a update on my work...

Check engine light came on a few days after. Turned out to be a 401 code, so I replaced the DPFG last night. So far so go. It was REAL bad!!!!

it seems that 100k+ of neglect, has given me a list of things that are "kinda" bad, and all put together brought o' windy to his knees

[96wWindstar180K]

s1120
Sorry I posted back but it didnt post up. I did my gaskets about 2 or 3 months ago. I have run injector cleaner for about 600 miles now. I replaced the tps, ccrm, cleaned the maf sensor and so on. On Wiswinds suggestion I am going to look at the dpfe much closer. I replaced it about a year or so ago. I know the problem with hesitation is probably something easy but it has me stumped. I may just bring it in and have someone diagnose it. Gald to hear yor up and running again.