How to step-by-step replace a head gasket on a 1998 Ford Windstar?

Answer 1

AnswerI have gone through this two times now on my Windstar! Both times because of a broken valve springs, one in each of the heads at different times! You have to: Remove the windshield wipers, the cover between the windshield and the hood. The rest of the wiper assy. also comes off by removing the bolts on the ends and around air ducts. Once you remove this you should have access over the entire top of the motor. Remove the air intake assys., throttle assy., spark plug wires from the front three spark plugs, top intake cover, bottom of the intake cover, the fuel injection manifold, coolant manifold, intake manifold, back three spark plug wires, remove coil pack along with the valve cover, remove the back exhaust manifold nuts and studs. It is VERY hard to reach the back exhaust studs and nuts. I found that loosening the nuts with a 13mm wrench and use a 5.5mm socket on the stud and take the stud all of the way out made it alot easier to work with. Use a 1/4" drive ratchet and socket on the studs. You WILL need the room!! Remove the the nuts from the exhaust headers, both front and back headers. Unbolt the a/c compressor. Use a six sided 15mm impact socket and a long handled 1/2"drive ratchet or breaker bar to loosen up the eight head bolts, 4 inside of the valve cover and 4 along the front edge of the head. The frond head removal will require you to remove the idoler pulley. this will help get one of the four bolts out that hold on the altenator. Then the valve cover,and the eight head bolts. I do not have the torque specs or pattern at this time for the head bolts. As you put the motor back together you will see that everything almost "snaps" back together. The hardest thing is the back 6 exhaust manifold studs because of the tight space and having to keep the gasket lined up all of the same time. I used 16 penny nails to hold it. The job is'nt really hard to do! Time consuming and at times a little agrivating but not hard at all. GOOD LUCK!!!!!!!!!!!!

I just finished doing that on my van and its also a 95. I removed the fans, then the A/C pump and the Power Steering pump, afterwards I removed the intake manifold. after that remove both exhaust manifolds and then you should have a clear room to take the heads off

You'll need to remove everything in the way, pull the rocker cover, remove the head then take the head to a machine shop to have it milled. Almost every time the head gasket blows, it's because the head is warped from engine overheating. Do NOT try to put it back together without having the head tested/milled by a qualified machine shop. You can't determine if it's flat just by looking at it. Only a machine shop can do that for you.

Answer 2

AnswerI have gone through this two times now on my Windstar! Both times because of a broken valve springs, one in each of the heads at different times! You have to: Remove the windshield wipers, the cover between the windshield and the hood. The rest of the wiper assy. also comes off by removing the bolts on the ends and around air ducts. Once you remove this you should have access over the entire top of the motor. Remove the air intake assys., throttle assy., spark plug wires from the front three spark plugs, top intake cover, bottom of the intake cover, the fuel injection manifold, coolant manifold, intake manifold, back three spark plug wires, remove coil pack along with the valve cover, remove the back exhaust manifold nuts and studs. It is VERY hard to reach the back exhaust studs and nuts. I found that loosening the nuts with a 13mm wrench and use a 5.5mm socket on the stud and take the stud all of the way out made it alot easier to work with. Use a 1/4" drive ratchet and socket on the studs. You WILL need the room!! Remove the the nuts from the exhaust headers, both front and back headers. Unbolt the a/c compressor. Use a six sided 15mm impact socket and a long handled 1/2"drive ratchet or breaker bar to loosen up the eight head bolts, 4 inside of the valve cover and 4 along the front edge of the head. The frond head removal will require you to remove the idoler pulley. this will help get one of the four bolts out that hold on the altenator. Then the valve cover,and the eight head bolts. I do not have the torque specs or pattern at this time for the head bolts. As you put the motor back together you will see that everything almost "snaps" back together. The hardest thing is the back 6 exhaust manifold studs because of the tight space and having to keep the gasket lined up all of the same time. I used 16 penny nails to hold it. The job is'nt really hard to do! Time consuming and at times a little agrivating but not hard at all. GOOD LUCK!!!!!!!!!!!!

I just finished doing that on my van and its also a 95. I removed the fans, then the A/C pump and the Power Steering pump, afterwards I removed the intake manifold. after that remove both exhaust manifolds and then you should have a clear room to take the heads off

You'll need to remove everything in the way, pull the rocker cover, remove the head then take the head to a machine shop to have it milled. Almost every time the head gasket blows, it's because the head is warped from engine overheating. Do NOT try to put it back together without having the head tested/milled by a qualified machine shop. You can't determine if it's flat just by looking at it. Only a machine shop can do that for you.