2003 Ford Windstar Tries to die when cold, engine light on!

ANDGRAND

MEMBER
2003 FORD WINDSTAR
6 CYL
FWD
AUTOMATIC
105,000 MILES

Once again the engine light came on! The van when it is cold and only in drive the van jolts and tries to die! You put it in park and it stops! It will also do it after the vehincle is hot and been driving for a long time! Ran computer check and it says it is running lean! Replaced almost all the cheap stuff now on to other more expensive stuff! Thank god hubby knows how to do it all! Also the brake like comes on while driving! And the ABS light comes on! We just put bran new EXPENSIVE top ofthe line brakes on and they squeek bad! Cleaned them and bled them still does it! What is going on? Heard that the intake gasket is plastic and melts in the 2003 is that true! Big job to do! We are out of patience!

1 Reply

F4I_GUY

MECHANIC
3,302 POSTS

On 2003's there is a TSB out. If you call Ford they will send you the gasket kit and pinch bolts needed for this.

No it is not a big job, I believe it takes only 2 hrs but can be done in a very short time. You must remove the intake plenum and replace that gasket, as well as replacing the fasteners that secure it to the upper intake manifold. Torque them to spec.

You may also need to replace your valve cover(s) as part as the TSB, but I believe that by 2003 they had this problem solved. Also, check your fuel pressure regulator vacuum hose for any cracks or leaks.