Windstar V6-232 3.8L (1995)
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T = Thump/Thud
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R = Rattle
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S = Squeak
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CR = Creak
Body: (S, CR, R)
Inspect the following:
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Cowl area spot welds - a loose or broken spot weld may be identified by corrosion forming around or through the weld. You may also tap lightly on
the spot weld; it should feel solid. Repair spot welds by drilling through the weld, installing a 3/16" blind stainless steel rivet, and then sealing the
rivet with Clear Silicone Rubber (D6AZ-19562-AA).
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Inner fender splash shield for contact with the subframe. Trim away any areas where contact can be seen.
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Radiator support brackets and mounting, and the cooler line clips.
Control Arm Strut: (C, P, S)
Inspect the following:
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Control arm strut-to-subframe bushing for wear and damage.
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Control arm strut-to-subframe bolt - tighten to 115-132 N.m (85-97 lb-ft).
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Control arm strut-to-lower control arm bolt - tighten to 115-132 N.m (85-97 lb-ft).
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Control arm strut for signs of damage or impact.
Engine/Transaxle Mounts: (C, P)
Inspect the following:
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Engine/transaxle mount for wear or damage.
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Front engine mount-to-subframe nut - tighten to 88-118 N.m (65-87 lb-ft).
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Front engine mount-to-engine bracket nut - for 3.8L tighten to 68-92 N.m (50-68 lb-ft), for 3.0L tighten to 41-54 N.m (30-40 lb-ft).
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Transaxle mount-to-subframe nut - tighten to 88-118 N.m (65-87 lb-ft).
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Transaxle mount-to-transaxle bracket - for 3.8L tighten to 68-92 N.m (50-68 lb-ft), for 3.0L tighten to 41-54 N.m (30-40 lb-ft).
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Transaxle support bar-to-transaxle bolts - tighten to 76-102 N.m (56-75 lb-ft).
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Transaxle support bar-to-engine/transaxle mount bolts - tighten to 88-118 N.m (65-87 lb-ft).
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Engine/transaxle mount-to-subframe bolts - tighten to 76-102 N.m (56-75 lb-ft)
NOTE:
IT MAY ALSO BE HELPFUL TO LOOSEN, NEUTRALIZE, AND RETORQUE THE ENGINE/TRANSAXLE MOUNTS TO ELIMINATE
BINDING CONDITIONS WITH THE MOUNTS.
Exhaust System: (C, P, R)
Inspect the following:
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Exhaust system hangers and supports should be intact and securely mounted.
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Exhaust system connections and condition. It may be helpful to neutralize the exhaust system as a binding condition in the exhaust may cause clunks,
pops, and rattles.
Front Brake Caliper: (C, R)
Inspect the following:
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Brake caliper bolts - 88-118 N.m (65-87 lb-ft).
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Pad and rotor condition.
