Here's a general guide. Specific steps and tool requirements may vary slightly depending on the exact engine in your Windstar (3.0L Vulcan or 3.8L Essex). Consult a repair manual specific to your vehicle's year and engine for detailed diagrams and torque specifications. A Haynes or Chilton manual is a great investment for DIY car repairs.
Tools you'll likely need:
* Wrench set: Metric, likely including 10mm, 13mm, and possibly others.
* Socket set: Metric, with extensions and possibly a ratchet.
* Screwdrivers: Both Phillips and flathead.
* Pliers: Needle-nose pliers might be helpful.
* New serpentine belt: Ensure you get the correct belt for your specific Windstar model and engine. The part number should be on the old belt or you can find it online using your VIN.
* Jack and jack stands (crucial for safety): Securely lift the vehicle. Never work under a vehicle supported only by a jack.
* Gloves: Protect your hands.
* Shop rags: To clean up any grease or oil.
* Optional: Belt tensioning tool: While sometimes possible to tension by hand, a belt tensioning tool makes the job significantly easier and safer.
General Steps (Consult your repair manual for precise details):
1. Locate the serpentine belt: It's the long belt running around various pulleys (alternator, power steering pump, water pump, etc.).
2. Identify the belt tensioner: This is a pulley with a mechanism to release tension on the belt. It usually has a bolt or lever.
3. Release belt tension: This is the trickiest part. You'll need to use a wrench or socket to loosen the tensioner. This will allow you to slip the belt off the pulleys. The exact method depends on your specific tensioner design. Your repair manual will show you exactly how to do this. Sometimes you can use a long-handled wrench or even a breaker bar on the tensioner bolt to create enough slack. A belt tensioning tool is highly recommended to prevent injury.
4. Remove the old belt: Once the tension is released, carefully work the belt off each pulley. It usually comes off in a specific order—again, your repair manual is your friend here.
5. Install the new belt: Carefully route the new belt onto each pulley in the correct order (reverse of removal). Make sure it sits correctly in the grooves of all the pulleys.
6. Release tensioner: Slowly release the tensioner, allowing the belt to seat properly onto all the pulleys.
7. Check belt tension: The belt should be snug but not overly tight. You should be able to deflect it slightly with moderate thumb pressure.
8. Reassemble: Put everything back together, ensuring all bolts are tightened to the correct specifications (as per your repair manual).
9. Check for leaks: Inspect for any leaks after starting the engine.
10. Reconnect battery terminal.
Important Considerations:
* Take pictures: Before you start, take pictures of the belt routing. This will be invaluable when installing the new belt.
* Repair Manual: A repair manual is strongly recommended. It will provide detailed diagrams and torque specifications, preventing damage to your vehicle.
* Engine Coolant: If you are working near the water pump, be aware of the potential for coolant spills.
* Professional Help: If you are uncomfortable with this task, take your vehicle to a qualified mechanic. A botched belt replacement can lead to serious engine damage.
This is a general guide, and the exact procedure might vary. Always refer to a repair manual specific to your 1995 Ford Windstar before attempting this repair. Your safety and the well-being of your vehicle depend on it.
