Top 10 1996 Ford Windstar Questions & Answers

follow your upper radiator hose back to the engine. That hose connects to the thermostat housing. Unbolt the housing and inside is the thermostat

The fuel pump power on the Windstar is controlled by a component called a Constant Control Relay Module (CCRM).
Its located located on the driver's side of the engine compartment.

the ignition switch is the electrical part behind the lock cylinder where the key goes in.

Ignition Switch Lock Cylinder
Lock Cylinder Functional
Removal

1. The following procedure applies to vehicles that have a functional ignition switch lock cylinder (11582) and keys. If the key numbers are known, the correct key can be made. Disconnect the battery ground cable (14301). For additional information, refer to Section 14-01 .
   

1. Turn the ignition switch lock cylinder to the RUN position.
   

1. Place a 3.17-mm (1/8-inch) diameter wire pin or small drift punch in the hole in the steering column shroud under the ignition switch lock cylinder. Depress the retaining pin while pulling out on the ignition switch lock cylinder to remove it from the housing of the steering column.
   

Installation

1. Install the ignition switch lock cylinder by turning it to the RUN position and depressing the retaining pin. Insert the ignition switch lock cylinder into the steering column housing. Make sure the ignition switch lock cylinder is fully seated and aligned in the interlocking washer before turning the key to the OFF position. This will permit the retaining pin of the ignition switch lock cylinder to extend into the hole of the steering column.
   

1. Using the key, rotate the ignition switch lock cylinder to make sure of correct mechanical operation in all positions.
   

1. Connect the battery ground cable.
   

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Ignition Switch Removal

1. Disconnect battery ground cable (14301). Refer to Section 14-01 .
   

1. Remove the upper steering column shroud (3530) by removing the four or five self-tapping screws. Remove key release lever (3F527) (if equipped).
   

1. Remove lower steering column shroud.
   

1. Disconnect the ignition switch electrical connector.
   

1. Rotate ignition switch lock cylinder (11582) to the RUN position.
   

1. Remove the two screws retaining ignition switch (11572).
   

1. Disengage the ignition switch from the actuator.
   

Item Part Number Description 1 11572 Ignition Switch 2 — Ignition Switch Lock Cylinder Housing 3 — Slot in Lock/Column Assembly A — (Part of 11572) Pin B — Alignment Mark
Installation
NOTE: A new replacement ignition switch assembly will be set in the RUN position as received.

1. Adjust the ignition switch by sliding the carrier to the ignition switch RUN position.
   

1. Check to make sure that the ignition switch lock cylinder is in the RUN position. The RUN position is achieved by rotating the ignition switch lock cylinder approximately 90 degrees from the LOCK position.
   

1. Install the ignition switch into the actuator. It may be necessary to move the ignition switch slightly back and forth to align the ignition switch mounting holes with the lock cylinder housing threaded holes.
   

1. Install retaining screws. Tighten to 5.6-7.9 Nm (50-69 lb-in).
   

1. Connect electrical connector to ignition switch.
   

1. Connect battery ground cable. Refer to Section 14-01 .
   

1. Check ignition switch for proper function, including START and ACC positions. Also, make certain that the column is in the LOCK position.
   

1. Install upper steering column shroud.
   

1. Install the lower steering column shroud and key release lever (if equipped).
   

It could all be related.P1537/38 are the intake manifold runner controls are stuck open.They are controlled by vacuum solenoids.The P0171 is bank one of the engine is running lean,usually caused by a vacuum leak, P0420 is catalytic converter efficiency code. The computer monitors the switch rate of the front 02 sensors and compares it to the switch rate of the rear 02 sensors to tell if catalytic converter is doing its job. Now if the front 02 is not switching properly then this will cause this test to fail and set this code.
Look on bottom section of the intake manifold at the back of engine(where tranny bolts up) you should see the vacuum motors there on the intake,these are the control motors for the intake manifold runners.Make sure the vacuum lines are hooked up and lines are not leaking. Also you will see a lever from it to intake make sure they move and are not binding.

3.0L or 3.8L engine?

please rate as fixed if this solves your issue.

Section 03-01B: Engine, 3.8L 1996 Windstar Workshop Manual
IN-VEHICLE SERVICE Water Pump SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fuel Line Disconnect Tool Set T90T-9550-S
Removal

1. Drain engine cooling system. Refer to Section 03-03 .
   

1. Loosen drive belt tensioner (6B209) and remove drive belt (8620). Refer to Section 03-05 .
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. Disconnect lower radiator hose (8286) from radiator lower hose tube (8291) and radiator (8005).
   

1. Disconnect radiator lower hose tube from water pump (8501).
   

1. Remove lower nut on both front engine support insulators (6038).
   

1. Lower vehicle.
   

1. Disconnect battery ground cable (14301). Refer to Section 14-01 .
   

1. Remove generator (GEN) (10346) from power steering pump support (3C511).
   

1. Position drain pan and disconnect power steering pressure line from power steering pump (3A674) using Fuel Line Disconnect Tool Set T90T-9550-S.
   

1. Remove power steering reservoir filler cap.
   

1. CAUTION: If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces.
   Disconnect water bypass hose (8597) and oil cooler hose (6B850) from heater water outlet tube (18663).
   

1. Remove retaining bolts and disconnect heater water outlet tube from water pump.
   

1. Remove A/C bracket brace.
   

1. Attach engine lifting eye to left-hand (front) exhaust manifold (9430).
   

1. Attach lifting equipment to engine lifting eye and raise front of engine approximately 51 mm (2.0 inches) to provide necessary clearance for water pump removal.
   

1. Remove water pump pulley retaining bolts and water pump pulley (8509).
   

1. Remove drive belt tensioner pulley retaining bolt and drive belt tensioner pulley (6B217) from power steering pump support.
   

1. Remove power steering pump support retaining bolts and nut. Place power steering pump and support assembly aside in a position to prevent fluid leakage.
   

1. Remove water pump retaining bolts and nuts and water pump. Discard used water pump housing gasket (8507).
   

Installation

1. NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant.
   
   Clean gasket surfaces on water pump and engine front cover (6019).
   

1. NOTE: The threads of the No. 1 engine front cover retaining stud must be coated with Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 before installing.
   
   NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the water pump housing gasket in position.
   
   Position a new water pump housing gasket on water pump housing sealing surface.
   

1. Position water pump on the engine front cover. Install retaining bolts.
   

1. Position power steering pump support and install retaining nuts and bolts. Tighten bolts and nuts to 40-55 Nm (30-40 lb-ft).
   

1. Install drive belt tensioner pulley and retaining bolt. Tighten bolt to 70-95 Nm (52-70 lb-ft).
   

1. Install A/C bracket brace.
   

1. Position water pump pulley on water pump hub and install retaining bolts. Tighten bolts to 8.0-11.5 Nm (71-101 lb-in).
   

1. Lower engine and disconnect lifting equipment from lifting eye.
   

1. Remove lifting eye from exhaust manifold.
   

1. Connect heater water outlet tube to water pump and install retaining bolts. Tighten bolts to 8-11.5 Nm (71-101 lb-in).
   

1. Connect water bypass hose and oil cooler hose to heater water outlet tube. Tighten clamps securely.
   

1. Connect power steering pressure line to power steering pump fitting.
   

1. Install power steering reservoir filler cap.
   

1. Install generator to power steering pump support. Refer to Section 14-02 .
   

1. Connect battery ground cable. Refer to Section 14-01 .
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. Install lower nut on front engine support insulators and tighten retaining nut to 88-119 Nm (65-87 lb-ft). Install lower nut of rear engine support insulator and tighten to 77-104 Nm (56-76 lb-ft).
   

1. Connect radiator lower hose tube to water pump. Install retaining bolt and tighten securely.
   

1. Connect lower radiator hose to radiator lower hose tube and radiator. Position hose clamps securely. Refer to Section 03-03 .
   

1. Lower vehicle.
   

1. Position drive belt over drive belt tensioner and release drive belt tensioner. Refer to Section 03-05 .
   

1. CAUTION: This engine has aluminum cylinder heads (6049) and requires a special corrosion inhibiting coolant to avoid cooling system damage. Refer to Section 03-03 for the coolant specifications.
   Fill and bleed cooling system with specified coolant.
   

1. Fill power steering pump reservoir with specified fluid.
   

1. Start engine and check for coolant and power steering fluid leaks. Service as necessary.
   
   
   Water Pump
   

Section 13-09: Gauges, Warning Devices — Chime System 1996 Windstar Workshop Manual
DESCRIPTION AND OPERATION Warning Chime Systems Three distinct sounds are used to indicate the area of concern. Seat belt warning generates 1 chime per second
key-in-ignition generates 2 chimes per second
headlight on generates 4 chimes per second.
Key-In-Ignition Warning The key-in-ignition warning will sound when the driver's front door (20125) is opened with the key in the ignition switch. It will continue to sound until the key is removed, the front door is closed, the ignition switch is turned to START or the vehicle speed is over 24 kmh (15 mph).

Safety Belt Warning When the ignition switch is turned to RUN or START from OFF or ACC, the chime will sound for six seconds or until the safety belt is buckled.

• The safety belt warning indicator lamp (10C859) will activate for 60 seconds or until the driver's safety belt is fastened. Both the chime and lamp activate at the same time.

Anytime the ignition switch is released from START and returns to RUN while the safety belt lamp or chime is activated, the safety belt warning lamp or chime will remain activated until either the timing sequence has been executed, or the safety belt is buckled.

Headlamp Switch On Warning The chime will be activated if the headlamps or parking lamps are ON, the key is not in the ignition and the driver's door is opened. The chime will sound at a rate of four per second.

please rate. thanks.

Heater Water Hoses




Item Part Number Description 1 N610956-S56 Screw 2 18472 Heater Water Hose, Supply 3 18472 Heater Water Hose, Return A — Tighten to 7-9 Nm (62-79 Lb-In)

Position the cylinder head on the cylinder block. Tighten the cylinder head bolts in 2 steps following the proper torque sequence. The first step is 37 ft. lbs. (50 Nm) and the second step is 68 ft. lbs. (92 Nm).

I didn't know which fuse panel you wanted so here are both. I'm not sure of the problem you are having but under the instrument panel is a relay box as well but didn't post those. this should all be in your owners manual if you have one. If you do not and would like one,you can email me at [email protected] with your make, model, year and what you are needing and I will be happy to email you a copy and don't worry there is no cost for it. anyway, here are your pictures/layouts and I hope they help....Good luck.

heres your manual http://www.motorcraftservice.com/pubs/content/~WOTWIN/~MUS~LEN/41/96winog1e.pdf