Tools You'll Likely Need:
* Socket set and wrenches: Various sizes, likely including metric.
* Pliers: Needle-nose and regular.
* Screwdrivers: Phillips and flathead.
* Hose clamps pliers: To remove and install hose clamps. Wide-jaw pliers *can* work but dedicated hose clamp pliers are much better.
* New heater hose(s): Get the correct length and diameter. Auto parts stores can help you identify the right part using your VIN.
* Drain pan: To catch coolant.
* Funnel: To refill the cooling system.
* Jack and jack stands (essential for safety): You'll need to get under the vehicle.
* Gloves: To protect your hands.
* Safety glasses: To protect your eyes.
* Shop towels or rags: To clean up spills.
* Coolant: Use the correct type for your Windstar. Check your owner's manual.
Steps (General - Consult your Repair Manual for Specifics):
1. Safety First: Park on a level surface, engage the parking brake, and use jack stands to safely lift the vehicle. Never work under a vehicle supported only by a jack.
2. Drain the Coolant: Locate the radiator drain petcock (usually at the bottom of the radiator) and carefully open it to drain the coolant into your drain pan. This is crucial to avoid a mess and reduce the risk of burns.
3. Locate the Heater Hose(s): Identify the hose(s) connected to the radiator that you need to replace. They are usually located at the top or side of the radiator. Some Windstars may have multiple heater hoses.
4. Remove the Hose Clamps: Use your hose clamp pliers to carefully loosen and remove the clamps securing the hose(s) to the radiator and heater core connections.
5. Disconnect the Hose(s): Once the clamps are off, gently work the hose(s) free from their connections. They might be stiff and require some effort. Be prepared for some coolant spillage even after draining.
6. Install the New Hose(s): Carefully slide the new hose(s) onto the fittings. Make sure they are seated correctly.
7. Secure with Clamps: Reinstall the hose clamps, making sure they are tightened securely but not over-tightened.
8. Refill the Cooling System: Carefully add the correct type of coolant to the radiator. Refer to your owner's manual for the proper coolant type and mixture (usually a 50/50 mix of coolant and distilled water).
9. Bleed the Cooling System: This is crucial to remove air pockets from the system. The bleeding procedure varies by Windstar model. Your repair manual will describe how to do this correctly; often, it involves running the engine with the heater on full blast until air bubbles are no longer visible in the radiator.
10. Check for Leaks: After refilling and bleeding, carefully inspect all connections for leaks. Run the engine for a short period and monitor for leaks.
11. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
Important Considerations:
* Accessibility: Working under a Windstar can be cramped. You might need to remove other components to gain better access to the hoses.
* Coolant is Toxic: Wear gloves and eye protection and avoid skin contact with the coolant.
* Corrosion: Old hose clamps can be very difficult to remove. Use penetrating oil to help loosen them. If they break, you may need replacement clamps.
* Repair Manual: This is absolutely critical. A generic guide like this can't replace the detailed instructions in a repair manual specific to your vehicle.
If you're not comfortable performing this repair yourself, take your Windstar to a qualified mechanic. A botched repair can lead to overheating, engine damage, and other serious problems.
