Seven problems related to radiator have been reported for the 1996 Ford Windstar. The most recently reported issues are listed below.
My 1996 Windstar had head gaskets repaired less than two years ago. At the time, the garage doing the work indicated the engine had a design problem, and the gaskets would probably, over time, fail again. This has happened, as radiator fluid has begun leaking once again into the engine block. This is a problem Ford knows exists with the 1996 Windstar, as it did with the 89-95 models, and it needs to be addressed.
Problems with head gaskets / if compression check had been done bending of piston rods may not have occurred. The consumer experienced, rough idle along with the smell of anti freeze(indicated a head gasket problem), the engine light had come on as a result of a misfire code(the radiator was flushed), there were noises that had come from the engine(lost power/slowed to a crawl), and the consumer was told that something had come loose in the engine. (there was an intermittent miss in cylinder #1) the rough idle and the smell of antifreeze was repaired, the service dealer recommended the consumer replace the engine.
This incident started when I had noticed a small amount of radiator fluid on the garage floor, and a slight smell of radiator fluid when I ran the heater. In addition, the check engine light had come on again in November 2002. I took the van to the apple valley Ford dealer and after diagnosing it, I was told the number 4 spark plug is stuck and the gasket needs to be replaced on the timing cover on the engine (this was the source of the radiator fluid leak). The dealers professional opinion was the head gasket is also bad, the head for the #4 plug would need replacing, and combined with the need to replace the timing cover gasket, they recommended a complete engine replacement at $4,400. I declined and took the van to another local mechanic, who unfortunately confirmed the diagnosis and indicated there were known problems and technical service bulletins for engine gasket replacements with Ford Windstar 3. 8 liter v6 engines in 1995. They also indicated they had started seeing this same problem turning up in 1996 models. They also quoted a similar number & recommended using a jasper engine instead of the Ford engine as the warranty is 75,000 miles. I also declined and the van is now sitting parked in my driveway while I continue to make car payments on a vehicle I can not drive for fear of engine failure.
Engine head gasket blewout, causing blue exhaust to come from tail pipe. This could have caused a fire. Dealer notified. Indicators are that radiator coolant had been leaking into oil causing 02 sensors to fail and be replaced. Dealer advised that entire engine be replaced.
Engine check light was on/ off. Consuemr sent vehicle to a radiator shop, and they referred her to dealer. Dealer has to replace gaskets because they have destroyed engine. Antifreeze was apparently leaking, it has to be filled frequently.
Engine was running rough; a lot of white smoke cme out of tailpipe. Radiator was losing antifreeeze every day. Took to dealership & mechanic would not look at vehicle. Contacted Ford manufacturer & csr indicated not under extended warranty, no repair will be done. Took to another dealership & was placed on diagnostic machine. Was technical service bulletin on head gaskets, but manufacturer was going by VIN.
Water level loss in radiator due to head gasket failure.