Stalled on highway

[knuckle ears]

95 windstar has stalled on the highway. Pulled over and it restarted. Drove another 10 kms and stalled again. Waited again, it started and drove another 100kms with no problem. Van is operating fine at this time but have another 300 kms to go. Any thought or help out there. 3.8 engine.

O2 sensor needs replacing form before, would this cause the problem?

[wiswind]

If you are not getting a CEL (Check Engine Light), I would suspect a fuel issue.
The fuel pressure and flow are NOT monitored by the PCM on the Windstar.
The fuel pump relay for on the '95 is located inside the Constant Control Relay Module (CCRM) which is a small metal box that is sandwiched in between the battery and the radiator support.
There are pictures of this on my '96 in my pictures.
Also, could be the fuel pump going.
First thing I would consider is the fuel filter.....as it is the cheapest and easiest.

If the problem was ignition, I would suspect that the CEL would be lit.
If it was the injector electrical drive.......PCM, connections, wires, I would also expect a CEL......and all the injectors acting up?......does not make sense.

EGR would make the vehicle run rough......but would seem to act differently than you describe......and also would light the CEL.

Do the Headlights get dim or blower motor slow down?...and I mean really noticable.....if so......battery and / or alternator.

Is the engine temperature going high?.....again....toward the top of the scale?

[knuckle ears]

Originally Posted by wiswind

If you are not getting a CEL (Check Engine Light), I would suspect a fuel issue.
The fuel pressure and flow are NOT monitored by the PCM on the Windstar.
The fuel pump relay for on the '95 is located inside the Constant Control Relay Module (CCRM) which is a small metal box that is sandwiched in between the battery and the radiator support.
There are pictures of this on my '96 in my pictures.
Also, could be the fuel pump going.
First thing I would consider is the fuel filter.....as it is the cheapest and easiest.

If the problem was ignition, I would suspect that the CEL would be lit.
If it was the injector electrical drive.......PCM, connections, wires, I would also expect a CEL......and all the injectors acting up?......does not make sense.

EGR would make the vehicle run rough......but would seem to act differently than you describe......and also would light the CEL.

Do the Headlights get dim or blower motor slow down?...and I mean really noticable.....if so......battery and / or alternator.

Is the engine temperature going high?.....again....toward the top of the scale?

The CEL was on before because of the O2 sensor needs replacing but other than that I had no over heating or dimming of lights. I had the A/c on and was just cruising along and then it died. 2 months ago i had the transmission rebuilt and they said the O2 sensor needed to be replaced. thats why the CEL is on at this time.
Going to the shop in the morning to replace the fuel filter. Guess I could try myself but no tools with me except a finger nail clipper and a comb.

Thanks for your help.

[wiswind]

Have the codes read, and get the actual numeric code(s).
Many auto part stores will do this for you for free.
Oxygen sensors are not a high failure item.
Vaccum leaks are, which give you lean codes P0171 and / or P0174.

[96wWindstar180K]

I would suspect the fuel pump. I have had a couple go out on other vehicles. You can crank and crank and nothing just as if it were getting no spark and ten minutes later it starts. If it is the fuel pump it probabley wont last long. Try AutoZone to check codes otherwise a good shop can put it on a scope to check the pump.

[Schrade]

This vehicle has a TFI ignition module.

It fails when hot; NO codes.

Google TFI ignition module.

The case in California has been settled.

I have a claim coming up soon on this issue.

Never mind the 'supposed' list of TFI-equipped vehicles, there's more. From '83 - '95.

[DRW1000]

Originally Posted by cbec1999

This vehicle has a TFI ignition module.

It fails when hot; NO codes.

Google TFI ignition module.

The case in California has been settled.

I have a claim coming up soon on this issue.

Never mind the 'supposed' list of TFI-equipped vehicles, there's more. From '83 - '95.

I was going to suggest the TFI module (but I didn't think they were still using them in 95). I had an 87 Escort that used to do the same thing. I had one replaced under warranty and then I bought one later from FORD and it failed and then I bought one from Walmart made by Wells Manufacturing (for a lot less than the Motorcraft version) and it lasted for years until I scrapped the car in 2002. I think the secret is using enough heat sink compound. The dealer installed part did not seem to have much compound and my theory is that ithey overheated.

[knuckle ears]

Is this vehicle OBDCII or can I get them by flashing the CEL light some how? I changed the fuel filter and seemed to run better but seems to be sluggish at times, no stalling though. Maybe needs an injector flush now ???

[knuckle ears]

Originally Posted by DRW1000

I was going to suggest the TFI module (but I didn't think they were still using them in 95). I had an 87 Escort that used to do the same thing. I had one replaced under warranty and then I bought one later from FORD and it failed and then I bought one from Walmart made by Wells Manufacturing (for a lot less than the Motorcraft version) and it lasted for years until I scrapped the car in 2002. I think the secret is using enough heat sink compound. The dealer installed part did not seem to have much compound and my theory is that ithey overheated.

I think you are right. I replaced the fuel filter and ran better but not good enough. I then replaced the fuel pump and the problem seems to have gone away.
But also I have had vehicles where the eletronics have given out and when I look at the heat sink, the compound is gone. Dried up. So now when I replace any electonic equipment I ensure their is ample compound. Even on my spark plugs and boots. It is a die electric silicone grease. I put it on every electical connection and wire I can find>

[wiswind]

Also, a clogged fuel filter will cause the fuel pump to work harder....against the back pressure.
In addition to the importance of heatsink compound (that is right in my field of knowledge), is NOT running around with "just enough" gasoline in the tank.
I'm talking about folks who stop and put $5 of fuel in when the low fuel light comes on......and go on until the light comes on......and toss another $5 in.......When $5 = 1/2 tank....not such a problem as today.
The fuel pump depends upon the gasoline in the tank for cooling. Low fuel (like 1/4 tank or lower) can rob the fuel pump of the cooling that it needs.
Unfortunately......with higher fuel prices......more people drive around with low fuel level in the fuel tank more often.
The