98 Windstar Loss of Power / Hesitation

[12Ounce]

I agree with first changing the "external" in-line fuel filter. It's a good first-step and maybe all you need. Under the floor pan in the driver's area. Be sure to use the Ford replacement filter ... and make sure they sell you the original spec little plastic clips that hold the filter in place ... the aftermarket ones can be dangerously insecure.

After that you can go after the pump/inlet screen/sock. The tank is huge ... but not that heavy when empty.. just clumsy. You will need a lot of "ground clearance" to get it out from under the vehicle. The pump has an inlet sock/screen that may be your only problem ... but its probably a good maintenance practice to go ahead and replace the pump. Depends. IIRC, the Ford pump costs around $250 -$300 ... so you may opt for just the sock replacement. Of course, you want to give the tank a good wipe out.

[tartersauce]

Pump and sock 144.
Complete unit with float for gauge, pump and sock 158.
Local parts store.. Not Ford stuff.

To gain access to the fuel pump, it is necessary to remove the fuel tank.

1. Depressurize the fuel system and remove the fuel tank from the vehicle. DRAIN TANK
2. Remove any dirt that has accumulated around the fuel pump module attaching flange, to prevent it from entering the tank during service.
3. Turn the fuel pump module locking ring counterclockwise using a locking ring removal tool or a brass drift and remove the locking ring. DRIFT AND HARD RUBBER HAMMER!! They dont say..
   
4. Remove the fuel pump module.
5. Remove the seal gasket and discard it.

To install:

1. Put a light coating of grease on a new seal ring to hold it in place during assembly. Install it in fuel tank ring groove.
2. Insert the fuel pump module into the fuel tank, then secure it in place with the locking ring. Tighten the ring until secure.
3. Install the tank in the vehicle.
4. Install a minimum of 10 gallons of fuel and check for leaks.
5. Install a pressure gauge on the throttle body valve and turn the ignition ON for 3 seconds. Turn the key OFF, then repeat the key cycle five to ten times until the pressure gauge shows at least 30 psi.
6. Check for fuel leaks at the fittings.
7. Remove the pressure gauge.
8. Start the engine and check for fuel leaks.

[Ulsterman]

I did change the fuel filter recently when I had the vehicle raised to install 2 new downstream O2 sensors following a code.
The filter I used was Purcolator from Advance Auto Parts which was the same model I'd used without any problem for the previous 30k miles. There were no noticable changes to the van running/not running before/after the change.
12Ounce is fitting a Ford/Motorcraft filter likely to make a significant difference to fuel pressure?

[tartersauce]

Originally Posted by Ulsterman

I did change the fuel filter recently when I had the vehicle raised to install 2 new downstream O2 sensors following a code.
The filter I used was Purcolator from Advance Auto Parts which was the same model I'd used without any problem for the previous 30k miles. There were no noticable changes to the van running/not running before/after the change.
12Ounce is fitting a Ford/Motorcraft filter likely to make a significant difference to fuel pressure?

If you did the filter already, then you have to move to the pump..
I dont think the fuel filter brand is gonna make much difference, unless You installed it backwards.. And that can be done on some...

If you have 30k on that filter, Change it again!!

[Ed_Strong]

Fuel Filters should be changed yearly. I don't know how many miles you put in your van every year, but 30K miles is a long time between changes. When I replaced the Fuel Filter on my van a few weeks ago after a year of use I drained the remaining fuel that was inside the filter on a pan and it was all dirty and murky (spelling). Also I could blow air thru the filter while it was still wet, I let it dry for like a ½ hour and I could not blow air thru it anymore. (Little trick my dad showed me)

If your filter had three times as much dirt as mine, the Fuel Pump might have been working too hard for too long causing it to fail or loose pumping strenght.

Purolator has stepped down really bad on quality and now I avoid its products. Thru the years I had a PCV Valve that was stuck open from when I first installed it, an Air Filter wasn't sealed properly and the wire mesh actually came thru the rubber seal allowing unfiltered air in the engine and my sister had a on Oil Filter explode on her Windstar a couple of months ago!

[12Ounce]

An aftermarket fuel filter is just fine ... I am really more concerned about those little plastic horseshoe clips ... I've seen some bad ones. If you already changed yours out and had no problems with leaks ... that issue must be OK for you.

Replacing the external filter again is a good first step. I am hopeful that either/both the external filter and/or the pump inlet screen is gonna get you going again.

[12Ounce]

Gee, Ed ... I've just started using Purolator oil filters!!!

[Ed_Strong]

Just keep an eye on the Oil Filter for leaks. The one on my sisters Windstar decided to crack after two or three weeks of being installed. Thank God they discovered it before taking the van on a long trip. And her van is a 3.0L engine which I believe uses the same filter but puts out less oil pressure than the 3.8L

[tartersauce]

Originally Posted by Ed_Strong

Just keep an eye on the Oil Filter for leaks. The one on my sisters Windstar decided to crack after two or three weeks of being installed. Thank God they discovered it before taking the van on a long trip. And her van is a 3.0L engine which I believe uses the same filter but puts out less oil pressure than the 3.8L

My uncle had a fram oil filter fail on a f150 few years ago. It killed the bearings and fram paid the for the cost of a replacment engine and labor.

[tartersauce]

Originally Posted by tartersauce

If you did the filter already, then you have to move to the pump..
I dont think the fuel filter brand is gonna make much difference, unless You installed it backwards.. And that can be done on some...

If you have 30k on that filter, Change it again!!

Fuel filters, Should be changed every 15k

Most of the newer cars and truck dont even have a fuel filter now. Just the sock in the tank. Our other 05 car, No filter. They call it a filter but its inside the tank, And its a Sock..
Kinda odd.. I guess they want the injectors to clog the little screen they have if any junk gets by the fuel pump sock.

[tripletdaddy]

What about putting in an after market filter? Are they out there? I would think one could take an earlier model filter and some fuel hose and clamps and splice one in.

[Ulsterman]

Yesterday I bought a dealer motorcraft fuel filter on the way home and fitted it to the van as I was going to jack it up anyway and have a good look around the fuel tank setup. The dealer quoted $258 for a new pump.
Afterwards no change to fuel pressure characteristics still a constant 10psi.
I'm going to order a fuel pump online somewhere and just wait for it to come in as I'm not going to be able to get near then van for a few days due to other committments.
My sincere thanks to everyone who has contributed to this post to date. It may be a few days but I'll post again once I have a new pump fitted and tested.

[Ed_Strong]

I'm not sure in the area where you live, but down here all Ford dealers are independent, so I would call all of the ones close to you including the Lincoln and Mecury and check prices. You'll be surprised at the difference on prices between them.

A few weeks ago when I had to replace my Damper/Balancer crankshaft pulley I was quoted $249 + shipping at GenuineFordParts.com and then I started calling around and found one at a Lincoln Mercury dealer for $130.

The dealer was about 100 miles away, so I also spent about $20 of gas to get there but the price was still good.

[searcherrr]

Have you ever experienced a "vehicle won't function at all event" ? IE: No electric to anything, no dome lights, no chime when key turned, no door lights , no instrument panel lights, no lights at all, etc..

Do you notice this happens more frequently in rain or high humidity days?

[Ulsterman]

The only experience like you describe occurred a few times when the battery was flat due to the interior lights not shutting off. The weather never seemed to affect this vehicle in any way.
Right now I'm tackling the low fuel pressure and have removed the fuel tank and am waiting for delivery of a new fuel pump I ordered online. Once that's fitted it's back to the drawing board if the problem persists but there are some very knowledge people on this site and I'm taking their advice.