I also have a 1996 Windstar that I needed to replace the engine on at 86,000 miles.. Same symptoms, check engine light on sometimes, but no problem until the head gasket gave up its ghost. Had a rebuilt engine installed at around 3300 dollars. Now its left front anti-lock is activating and I can't find out why. Tone wheel looks good and I replaced the speed sensor with a new ford oem one.
I have a 1996 Windstar GL with the 3.8 liter engine. Paid north of $1,500 about two years ago for the head gasket repair when the car had 86K. The car has seen only light use in the past two years, but now, at 99K, the check engine light came on, the #4 cylinder is mis-firing and the mechanic tells me the cylinder is leaking again. I don't know what's more frustrating -- the fact that Ford made a defective vehicle and wouldn't stand by their customers as they did on the '95s, or the fact that the expensive fix was very temporary. The car has had numerous other reliability and quality problems as well.
All I can do is vote with my wallet -- I won't be buying anymore Fords.
I have had to replace the engine on my 96 Ford Windstar twice.
I also have a 1996 windstar. I am getting ready to put in my 2nd Engine also. Will never buy another Ford Product!
1996 Windstar owner here. At 116,000 miles and in the last 6 months I've replaced struts, strut plates, front steering arms, both front wheels had bearings go, alternator died, an intake gasket just was repaired and it still runs poorly!!
No more FORDS for me!
I am also an UPSET owner of a 1996 Ford Windstar. I have had nothing, but problems since I bought the van only a year and a half ago. First the oil pump went, replaced it and it went again causing engine damage. Replaced the engine and here only 5 months later I am dropping off the van again today for problems. Loss of pick up, running rough, and surging. Also, my door ajar light has been stuck on for 9 months and occasionally the door ajar bells will ding forever even when all doors are closed tightly. Sometimes when I turn on my head lights a bell will ding until I turn them off. Kind of a problem when you need to drive at night. I am going to trade it in soon and will not be buying another FORD. Anything, but, as far as I am concerned right now!!
I am a 1996 ford windstar owner. I bought the van just over a year ago, from a ford dealership. The van was in excellent shape, and drove excellent. For about 5 months. It started with the brakes, then the EGR sensor, then the EGR valve its self, I still need to replace the air tube from the manifold to the EGR valve. I just replaced my master cylinder. I did have a broken spring, so I replaced my struts and springs with quick struts. Later I found out springs were a recall, and ford did reimburse me for the whole bill. Now my problem is with the check engine light, it either stays on or blinks. I keep being told it is the EGR valve, but its been replaced. The van looks great, but it hesitates when you first start out, then around thirty you can hear a thumping sound when you press to accelerate, and as soon as you take your foot off the gas it stops. Well thanks to everyone elses comments for this vehicle I think I found the problem, which no one has been able to answer. I think now it is the head gaskets, because it seems it is running one cylinder short, I smell anti-freeze, and that would explain the hesitation and the thumping I hear on acceleration. I also found that I have a broken sway bar, and it seems a lot of people in my area are experiencing the same problem, because all the junk yards are out of them and say their selling like hot cakes. Also ford dealers have to order the part, because they are out of them, due to selling so many. I do all my own repairs, so if any one out there needs help or advice, and cannot get answers e-mail me at twoangels@adelphia.net or just call me 716-825-2603 my name is mark. I really do like ford products, but I also hope that they will stand up and take responsibility for their product, meaning the engine, mainly the head gasket problem.
I also own a 1996 Windstar GL 3.8L have had it for the past two years with 144,000 miles on it now, Originally had 120k when first purchased. An so far the only thing I've had go bad was a mis-fire in Cylinder #3 which has triggered the Check Engine Light. I plan to get another tune-up an hopefully that will fix the issue an there won't be any serious problem in the near future.
I own a 1996 windstar 3.8 GL. Bought it brand new. It has now 168,000 kilometers. First 3 years of ownership, had the transmission replaced. So far all the major parts replaced for the past 10 years are alternator, tie rod ends, upper and lower control arms, front coil springs, EGR, ignition, front door ajar sensors. Currently experiencing a rattling noise which I suppose is not hard to fix. Engine Light came out and diagnostics indicate this vehicle has the IMRC problem. Don't know how much it will cost to repair. SO far the vehicle still runs good and I'm kind of satisfied to have it served me for the last 10 years. Overall the service cost for this vehicle compared to my Nissan vehicles are low.
My 1996 GL has given me no problems to speak of for the past 201,000 miles. recently I had the transmision rebuit, but after 200,000 I am very happy with the vehicle.
July 25, 2007.
I also have a 1996 Ford Windstar. I have run into all the problems all you other people have. Still having a problem with the blinking engine light. I am receiving the codes 302, 401. Starting from cold, I could drive 1000 miles with no blinking lights. The minute I shut down the engine and restart I receive these codes. Seems to only happen when it is warm and eventually the blinking light will go out while driving. I do not believe it is a head gasket as I have checked for leaks. Also the blinking lights go away after driving a few miles. If it is extremely warm it may take me 20 miles before it goes off. I have done most of the repairs all of you have done. Cleaning the EGR ports and all the rest. I suspect the egr valve is sticking as the engine heats up. If anyone has a fix for this just send me an e-mail, n2cyj@bluebottle.com I am using a spam free e-mail service and you may have to reply to confirm your e-mail address. Thanks Dan Niagara Falls New York.
I bought a 96 Ford Windstar less than a month ago from a used car dealer (not Ford) with 130,000 miles on it. The door ajar light is constantly on and now the emergency lights <flashers> go on and off intermittently without anyone having pressed the button. Does anybody know what this means?
Regarding the previous comment about doors ajar light. Most likely caused by the latches on the rear access door. Get a spray degreaser and soak the latches on both sides. Whatever oil was on them collects dust and dirt and prevents it from latching totally. Mine now (1996) has been OK for over year now. But now I have a problem with the rear window wiper. I guess I need to get a repair manual to check the wire harness.
Like the many above, not pleased with Ford Motor Company.
We bought our '96 Ford Windstar brand new in Madison Wisconsin, at 40,000 miles the head gasket went out, the
local dealer would not stand behind it. The sway bar broke,
check engine light and ABS light always coming on, door adjar and internal light won't turn off. Numerous sensors
needing replacement, this is the worst vehical we ever owned.
It has cost us tremendously in repair bills, and yes we
will never buy another Ford product.
I have a 1996 Windstar with a rod hanging out of the block most probably caused by a head gasket leak. It has 80,000 miles on it. I'll be attempting to replace the engine myself with a remanufactured one sometime in the next month.