General Steps (This is a simplified overview and may not be entirely accurate for your specific year):
1. Safety First: Disconnect the battery negative terminal. Use jack stands to securely support the vehicle. Wear safety glasses and gloves.
2. Preparation: Gather all necessary tools and parts. This will include:
* New axle beam assembly: Ensure it's the correct part for your year and model.
* Jack and jack stands: Crucial for safe vehicle support.
* Wheel chocks: To prevent accidental movement.
* Sockets, wrenches, and ratchets: A comprehensive set for various bolt sizes.
* Torque wrench: Essential for tightening bolts to the manufacturer's specifications.
* Penetrating oil: To help loosen rusted bolts.
* Pry bar: May be needed to separate components.
* Wheel alignment tool (optional but recommended): A post-repair alignment is essential.
3. Brake System Disassembly: This is crucial and may vary depending on your Windstar's year. You will likely need to:
* Remove the wheels.
* Disconnect brake lines (carefully, to avoid fluid spillage). You may need a brake line flaring tool and new fittings if the lines are damaged.
* Remove the brake calipers and rotors.
4. Suspension Component Removal: This will involve disconnecting various components connected to the axle beam, including:
* Control arms: These will need to be disconnected from the axle beam and frame.
* Shocks/struts: These will likely need to be removed.
* Stabilizer bar links: Disconnect these from the axle beam.
* ABS sensors (if applicable): Carefully disconnect these to avoid damage.
5. Axle Beam Removal: This is often the most challenging part. You'll need to carefully unbolt the axle beam from the vehicle's frame. There will likely be several bolts securing it. Use penetrating oil to help loosen rusted bolts.
6. Axle Beam Installation: Install the new axle beam, reversing the removal process. Pay close attention to the orientation and alignment of all components.
7. Reassembly: Reinstall all previously removed components, ensuring everything is properly connected and tightened to the correct torque specifications. Reconnect brake lines and bleed the brake system (if necessary).
8. Wheel Alignment: Take the vehicle to a professional for a wheel alignment. This is crucial for safe and proper handling.
Warnings:
* This is a complex repair. Attempting this without experience can result in damage to your vehicle or personal injury.
* Consult a repair manual: A factory service manual is indispensable. Generic instructions are insufficient.
* Brake system work requires care and knowledge. Improper bleeding of the brake system can lead to brake failure.
* Safety is paramount. Use jack stands, chocks, and wear appropriate safety gear.
Recommendation: Unless you have extensive mechanical experience working on suspension systems, it's strongly recommended to have this repair done by a qualified mechanic. The cost of repair may be less than the cost of incorrectly performing the repair yourself and causing further damage.
