2003 windstar barely moves
I have a 2003 windstar that started out having a cylinder 2 misfire, so I replaced spark plugs and then it went to cylinder 2 and 3 misfires and started backfiring and smelling like gasoline, but there is no fuel leaking anywhere. I had it towed to a garage, and they could not find out why it was running rough and told me that when they did a compression test, cylinder 2 only went to 60 lbs and 3 went to 100 lbs. Also, when I checked out the codes in OBD, it came up with P0230, P0231, P0402, P0171, P0302, P0303 & P0316. When I was told of the compression test, I believed that it sounds like I would need engine overhaul, which is more than it is worth. I decided to just bring it back home, and we could not get it to drive over 20 mph, and when I got it home, the hoses from the dpfe sensor were blown off. I tried to put them back on, but they would not stay on. Any ideas of why it is doing that? Or, should I just send the old van to the scrap yard and say goodby to it after 19 faithful years and 216,000 miles?
Unless you are willing to put a lot of money into the engine, haul it to the scrap yard. A cylinder with 60 psi will never do its share of the work. No need to address hoses blowing off and all the codes until the compression issue is fixed.The van is not worth putting the money into.Having two adjacent low cylinders probably means a blown head gasket, cracked head or even worse.
Is the transmission slipping? With 216k miles, many codes present, you may have several issues going on. You still have basically two dead cylinders.For a decent running engine, all cylinders should be within 15% from lowest to highest.
If you drove the van for a long time with two dead cylinders, there's a good chance the converter is damaged as well. I would part ways with your vehicle before sinking a lot of money into it and gaining little progress,especially if you pay someone to fix it.
If you drove the van for a long time with two dead cylinders, there's a good chance the converter is damaged as well. I would part ways with your vehicle before sinking a lot of money into it and gaining little progress,especially if you pay someone to fix it.
What I meant by "barely moves" is that it won't go over 15-20 mph, and it blows the vacuum hoses off the dpfe sensor. The transmission shifted fine until this problem surfaced and engine had a miss with only cylinder 2 misfire, but it backfired several times last time I drove it. Took it to mechanic and he did compression check, and came up with readings I mentioned in my post.
The issues with the engine could have ruined the catalytic converter thus blocking exhaust flow. A vacuum gauge can be used normally to diagnose but could be difficult with the compression issues. If you can easily disconnect it and try a test drive. You can do a lot of work on it but still have an engine in very bad shape. Posibilities include a burned valve, cracked hea, blown head gasket or piston ring issues. If there is a ring issue, combustion gases cound blow by the rings, putting pressure in the crank case sufficiently to blow hoses off there fittings.If you pull out the PCV valve, there should be vacuum present but if a lot of smoke blows out the PCV grommet, thats blowby.
You’re so right—eternal repairing to no avail. I’ve got a similar bag of bones with my ‘03. I’m competent enough to install engines and transaxle as in the past, but I’ve made mistakes that required double duty. So I’m battling (SOOO) many issues. First this was a salvaged engine that I desperately purchased despite its advertised lower mileage and cost—which should’ve drawn a red flag. Lower SHOULD mean higher, but ignorance was bliss—until it wasn’t. Being proactive I safeguarded my investment with new oil-pump, water-pump and timing chain. I foolishly confused which harmonic balancer was on which engine—and there seems to have been a difference. I thought I’d figured out which was which, but I’m not so sure now. I did a horrible job of realigning the cam phaser the first attempt but redid that well enough. I’m now second guessing whether I missed a tooth on timing set change—or did I install the new chain with the balance shaft out of phase. This idea comes from an audible knocking or tapping sound that I’ve isolated to the engine by running without the belt. Most recently I had to stop a massive leak from the bell housing that turned out to be a dislodged torque converter seal. While I had it out I broke it open and installed a new chain (old was stretched and worn) and stator support (w/bushing) and opened the drainback hole a little. I replaced the torque converter(w/input-shaft bushing) to ensure I’d circumvent any contamination from frictions or steels when it was oil starved. I did some metalwork on the subframe that I bent one day bottoming out. Cut out the section above the dent and used mapp gas and a 5lb hammer with a ball peen as an anvil, and slowly straightened it. I welded back the section ground and smoothed; then sealed with paint…..good as new. The jolt also tore the bolt hole for the LCA. Took two large washers and welded to front and back of that hole re-drilled it…good as new. Back up and running I’m still hearing that incessant knocking. Im beginning to worry that whatever it is could’ve helped to dislodge that converter seal. Then I’m deducing that burnt oil smoke out the tail pipe could indicate a valve seal problem or bent valve or push rod or both—which could account for the tapping. While changing a cracked oil pan, I took an opportunity to try and replicate the tap by shaking the con-rods. Some thrust clearance but no journal/bearing slacknesses.
“Hi my name is Marc—I’m a workaholic!!!”
So my first thought about your issue is, could you have cross-threaded the spark-plug initially when checking cylinder 2 and/or created a compression leak right at that point—the smell of fuel could be an indication. Since gasoline evaporates so quickly you won’t see the leak after it does. If you’re already considering junking it why not wrapping the threads on that spark-plug and see what happens.
“Hi my name is Marc—I’m a workaholic!!!”
So my first thought about your issue is, could you have cross-threaded the spark-plug initially when checking cylinder 2 and/or created a compression leak right at that point—the smell of fuel could be an indication. Since gasoline evaporates so quickly you won’t see the leak after it does. If you’re already considering junking it why not wrapping the threads on that spark-plug and see what happens.
Last edited by daddyblaize; Mar 23, 2022 at 09:08 AM.
You’re so right—eternal repairing to no avail. I’ve got a similar bag of bones with my ‘03. I’m competent enough to install engines and transaxle as in the past, but I’ve made mistakes that required double duty. So I’m battling (SOOO) many issues. First this was a salvaged engine that I desperately purchased despite its advertised lower mileage and cost—which should’ve drawn a red flag. Lower SHOULD mean higher, but ignorance was bliss—until it wasn’t. Being proactive I safeguarded my investment with new oil-pump, water-pump and timing chain. I foolishly confused which harmonic balancer was on which engine—and there seems to have been a difference. I thought I’d figured out which was which, but I’m not so sure now. I did a horrible job of realigning the cam phaser the first attempt but redid that well enough. I’m now second guessing whether I missed a tooth on timing set change—or did I install the new chain with the balance shaft out of phase. This idea comes from an audible knocking or tapping sound that I’ve isolated to the engine by running without the belt. Most recently I had to stop a massive leak from the bell housing that turned out to be a dislodged torque converter seal. While I had it out I broke it open and installed a new chain (old was stretched and worn) and stator support (w/bushing) and opened the drainback hole a little. I replaced the torque converter(w/input-shaft bushing) to ensure I’d circumvent any contamination from frictions or steels when it was oil starved. I did some metalwork on the subframe that I bent one day bottoming out. Cut out the section above the dent and used mapp gas and a 5lb hammer with a ball peen as an anvil, and slowly straightened it. I welded back the section ground and smoothed; then sealed with paint…..good as new. The jolt also tore the bolt hole for the LCA. Took two large washers and welded to front and back of that hole re-drilled it…good as new. Back up and running I’m still hearing that incessant knocking. Im beginning to worry that whatever it is could’ve helped to dislodge that converter seal. Then I’m deducing that burnt oil smoke out the tail pipe could indicate a valve seal problem or bent valve or push rod or both—which could account for the tapping. While changing a cracked oil pan, I took an opportunity to try and replicate the tap by shaking the con-rods. Some thrust clearance but no journal/bearing slacknesses.
“Hi my name is Marc—I’m a workaholic!!!” So far, not everyone has been able to find quality images for every theme yet. And I just had to find something related to metal forging and so on, because I did a special site on this topic. Fortunately here anvil images are very much, I did not even expect to find so many. Now the site is already launched and there used these cool images, maybe you can use them.
So my first thought about your issue is, could you have cross-threaded the spark-plug initially when checking cylinder 2 and/or created a compression leak right at that point—the smell of fuel could be an indication. Since gasoline evaporates so quickly you won’t see the leak after it does. If you’re already considering junking it why not wrapping the threads on that spark-plug and see what happens.
“Hi my name is Marc—I’m a workaholic!!!” So far, not everyone has been able to find quality images for every theme yet. And I just had to find something related to metal forging and so on, because I did a special site on this topic. Fortunately here anvil images are very much, I did not even expect to find so many. Now the site is already launched and there used these cool images, maybe you can use them.
So my first thought about your issue is, could you have cross-threaded the spark-plug initially when checking cylinder 2 and/or created a compression leak right at that point—the smell of fuel could be an indication. Since gasoline evaporates so quickly you won’t see the leak after it does. If you’re already considering junking it why not wrapping the threads on that spark-plug and see what happens.
If that vehicle has a 3.0 engine, they were known for losing valve seats and a recon head was a simple cure. With that many miles on the engine there could be problems with the better compression blowing past the worn rings.


