Five problems related to gas recirculation valve (egr valve) have been reported for the 1996 Ford Windstar. The most recently reported issues are listed below.
12-15-97 at 21,145 miles I reported noticing the coolant level always being low. No leak was found and I was told there must be a leak somewhere in the radiator. 12-27-99 at 56,526 miles I began having a "cold start" problem. It acted like it was not getting fuel. 12-1200 at 74,306 miles I had the same "cold start" problem and the fuel filter was repaced. 12-22-00 at 74,930 a new thermostat & gasket. 12-29-00 at 75,113 a fuel pressure regulator. 03-02-01 at 77,569 miles a new fuel pump relay(ccrm), fuel pump and pvc valve. 09-11-01 at 87,907 miles a mult-function switch. 01-31-02 at 95,069 miles a second ccrm relay. 03-06-02 at 99,348 miles on an 80 degree day "no start" same symptoms as "cold start" problem. Instead of not getting fuel it is suspected it is flooding. 4-23-02 at 99,348 miles cold start problem, fuel injectors cleaned. 05-30-02 at 101,330 miles wouldn't start, no fuel pressure-intermittent. Had to have it towed. 6-7-02 at 101,388 miles "no start" problem. New fuel filter, fuel pump and sender o-ring. 12-01-2-01 109,530 miles van started steaming - appeared to be a coolant leak or broken hose. Added coolant direct in radiator. I have carried own coolant and added frequenlty since 1997, when I was told there must be a leak in the radiator. I could not find any trace of such a leak by putting cardboard under van. Suspected the plastic coolant container had a leak. No coolant leaks where ever found during routine oil changes. 12-04-02 109,568 m,iles found leaking front timing cover gasket. Replaced headgasket and all else that goes with it. Cost of repair $1,915. 21. I believe the headgasket defect has been the problem all a long, costing me a small fortune.
Head gaskets are designed to last the lifetime of a vehicle. They are not routine maintenance items in the Ford owner's manual. Ford extended the warranty on the 1995 Windstar head gaskets twice (5 years, 60k miles and then to 100,000 miles). Even though no major changes to the engine block were made on the 96 Ford winstar, Ford has refused to accept responsibility for repairing this know defect on my vehicle. In fact it appears that Ford is aware of the condition as they issue a technical service bulletin in October 1999 for the 1996 Windstars (TSB 90-20-7). The cost of the repair to me was $1,357. 84. What is even more troublesome to me is Ford's complete lack of integrity and honesty by not fully disclosing this known defect to its customers. This is an injustice to all americans who purchased this product. I hope you will help do something about this problem.
Check engine light comes on< goes off< comes on< goes off< comes on< stays on< goes off! and the dealership (greene Ford, gainesville, GA. ) always has a different reason for the problem at a cost of approximately. $600 or more to fix each time, to no end. The first time the check engine light came on the imrcs were suppose to be the problem according to the dealerships disagnostics test (cost $80. 00) they replaced and supposedly fixed the problem, (cost $560. 00). Light came on next day while taking a family vacation out of state. Had an independent machanic perform a tune up on vehicle, replaced plugs, wires, oil change, throttle body cleaned (cost $223. 00) the check engine light came back on within two days. Upon the next return to the dealership the diagnostics test (cost another $80. 00) reported a code egr insufficient flow and a #4 cylinder misfire (est. Repair costs $600. 00). Had a dpfe sensor replaced ($76. 00) the check engine light came back on! it is amazing to me that these so called dealerships (experts) with their so called (diagnostics tests) have not the foggiest clue about how to fix this problem. It is also disturbing that after reveiwing the number of complaints on this website, that NHTSA has not ordered Ford to stop playing games and force a recall for these problems. It is apparent that others had the same symptoms and problems in the past that never get resolved until the head gaskets fail and the repair bills go from $600. 00 to $2000. 00. I am accusing Ford of knowingly and without regard to the best intrests of their customers allowing major problems to exist and persist in an effort to increase their profits at the customers expense. Ford corparation should be assamed, but they have shown no acceptance of responability. And the dealerships are no better, everytime we discuss this problem with them, we get different answers and costs from day to day and it appears if you complain to much you get to pay even more. Thanks Ford, for nothing!.
The defective design of the air intake valve located on the driver's side over the wheel well housing, water accumulated and clogged the air intake valve, causing the engine to stall while driving which almost resulted in an accident.
Manifold gasket and head gasket failed causing the vehicle to use excessive amount of coolant and check engine light was illuminated injectors and egr ports were cleaned, 2 months later when the vehicle began smoking thick white smoke, this dealer found that the head gasket had blown and that the consumer was 12 days late for the manufacturer's recall.