Windstar V6-232 3.8L (1995)
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Strut-to-knuckle pinch bolt - tighten to 115-132 N.m (85-97 lb-ft). If the bolt was loosened, replace it with a new bolt as the nylon locking feature
may be worn.
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Alignment plate spot welds - replace broken welds with stainless steel blind rivets. Refer to the weld replacement procedure in the appropriate year
Windstar Service Manual, Section 04-00, Suspension Service.
NOTE:
THE ALIGNMENT PLATE WELDS MAY ALREADY BE DRILLED OUT AND REPLACED WITH RIVETS AS THE RESULT OF A
PREVIOUS ALIGNMENT. IN THIS CASE IT IS IMPORTANT TO VERIFY THE RIVETS ARE SECURELY HOLDING THE PLATE IN
PLACE.
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Shock tower-to-inner tender welds if a "creaking/oil canning" noise is heard. A loose or broken spot weld may be identified by corrosion forming
around or through the weld. Tap lightly around 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 body seam sealer or RTV such as Clear Silicone Rubber (D6AZ-19562-AA).
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Stabilizer bar links upper and lower nuts - tighten to 90-100 N.m (66-74 lb-ft).
NOTE:
WHEN USING CHASSIS EARS TO DETERMINE IF THE STRUT IS PRODUCING AN UNACCEPTABLE NOISE, IT IT IMPORTANT TO
REMEMBER THAT THE CHASSIS EARS CAN DETECT FLUID MOVEMENT NOISES NOT AUDIBLE FROM THE DRIVER'S POSITION.
ONCE YOU HAVE PINPOINTED THE SOURCE OF THE NOISE AS THE STRUT, MAKE SURE THE NOISE CAN BE HEARD FROM THE
DRIVER'S POSITION PRIOR TO REPLACING THE STRUT. IF YOU ARE IN DOUBT, COMPARE THE NOISE ON A SIMILAR VEHICLE.
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After all the Strut Top Nut areas have been inspected, and the noise has been unaffected, replace the strut.
Subframe: (C, P, S, CR)
Inspect the following:
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Subframe condition for evidence of damage from impact. A damaged subframe should be evaluated by a qualified body shop to determine if
replacement is required.
NOTE:
BROKEN WELDS ON THE SUBFRAME SHOULD NOT BE REPAIRED.
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Subframe weld condition. For squeaking or creaking noises, the general condition of the subframe welds should be inspected. A loose or broken weld
may be identified by corrosion forming around or through the weld. Tap lightly on the weld, it should feel solid. Replace the subframe if loose or
broken welds are found.
Subframe Insulators: (C, P, CR)
Inspect the following:
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Subframe insulators. Windstars built before 1/1/96 may experience a clunk, pop, or creaking noise on heavy acceleration or deceleration in the floor
pan area. This may be the result of movement between the body and subframe. A revised insulator is available; refer to TSB 95-24-5 if within the
applicable build dates.
NOTE:
WINDSTARS BUILT AFTER 1/11/96 ARE BUILT WITH THE REVISED SUBFRAME INSULATORS. IF A NOISE IS STILL COMING
FROM A REVISED SUBFRAME INSULATOR, INSPECT THE "NIBS" IN THE UPPER SURFACE OF THE INSULATOR. THE "NIBS" BITE
INTO THE FRAME AND PREVENT BODY MOVEMENT. REPLACE THE INSULATOR IF THE NIBS SHOW EVIDENCE OF WEAR.
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Subframe insulator condition. Replace the insulator if deterioration is found in the rubber absorbers. Also, check for evidence of debris trapped in the
insulators.
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Subframe insulator mounting bolts (4). The bolts should be torqued to 80-90 N.m (59-66 lb-ft). If the bolts have loosened, replace them with new
bolts, as the nylon locking feature may be worn.
Tie Rod Ends: (S, CR)
Inspect the following:
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Tie rod ball stud where it connects to the steering knuckle. The stud may be worn. Replace the tie rod end if worn.
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Tie rod boot. If the boot is torn the stud may be rusted or seized. Replace the tie rod if the boot is damaged.
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Tie rod ball stud nut. The nut must be secure and the coffer pin in place.
