Hi folks, I am posting this in the Aerostar forum because there is no "Windstar" forum and I am hoping that detail willl not matter here.

My challenge is this: About three months after purchasing my 98 Windstar Limited 3.8L I have run into "service engine soon" issues. It started with the O2 sensors being bad. The mechanic replaced them and within two weeks the light came on again with the same error code. We had the mechanic clear the codes and turn off the light as he expected it was just the computer resetting itself. Well, a month later the light came on again and this time it had to do with "cylinder 1". We discussed it with the mechanic and grudingly agreed to a full tune-up (plugs, wires, filters, etc.) That was supposed to have fixed the problem. Not so. Within two weeks the light was on again and with the same "cylinder 1" error code. So, the mechanic decided it was the coil pack and he promptly replaced it. Now three days later the light is on yet again showing cylinders 1 and 2 to be running lean. Well, this can't be because we changed out the O2 sensors just a few months ago. What can it be?

Is it possible that the diagnostics leading from the cylinders to the computer module is now defective?

Oh yeah, the care runs fine until the light comes on, then it runs a bit rough, then when the codes are cleared and the light is off, it runs smooth as silk. Any ideas? It's a V6 3.8L 1998 Windstar

 

You mechanic should know this one.

Intake gasket leaks on the 3.8L have been known for over a decade which is more than likely causing your lean codes/CEL.

Another possibility is the MAF is dirty. It is worth trying to clean it with MAF cleaner.

If he trys to replace the computer, go else where, that would be the last thing to look at.

 

Thank you nighthawk. I will take this information to the mechanic with me. This is a new thing for him. He's never worked on a Windstar before.

 

The Aero's with the 4.0L OHV V6 also have/had more than their share of intake manifold leak problems, different engine design.

Expensive repair at a shop, 3.8L transverse V6 in cramped engine compartment of a Windstar replacing the intake manifold lower gaskets. Minimum $1000 at an ASE certified shop

the engine and transmission problems in the WS killed it quickly, Aero series last far longer.

the chemicals in coolant antifreeze quickly contaminate and kill a new O2 sensor and destroy crank bearings. these usually leak coolant along with sucking in extra air into the cyls.


3.8 intake gaskets (lots of pics) - Taurus Car Club of America : Ford Taurus Forum

Coolant Leaking From Intake Gaskets (Ford 3.8L)

http://townhall-talk.edmunds.com/direct/view/.f18fcc8

http://www.motor.com/article.asp?article_ID=1477

http://www.automotiveforums.com/t527...ke_gasket.html

 

Thank you 4wdr. I sure hope it is that. I can't afford to shell out 1g all at once.