Here's a general outline of the process:
1. Preparation:
* Safety First: Work in a well-ventilated area. Wear safety glasses and gloves. Support the vehicle securely on jack stands, never rely solely on a jack. Disconnect the negative battery terminal.
* Gather Tools and Supplies: You'll need a jack and jack stands, various wrenches and sockets (metric), a drain pan, a new oil pan gasket (crucial!), new oil and filter, possibly a sealant (check your manual for recommendations), putty knife or plastic scraper, possibly a torque wrench.
* Drain the Oil: Warm the engine slightly to thin the oil, then drain the oil into your drain pan using the oil drain plug.
* Remove Related Components: This is where the manual is essential. You'll likely need to remove components obstructing access to the oil pan, such as:
* Lower engine splash shields/covers: These often need to come off first.
* Possibly the exhaust system: Parts of the exhaust system might need to be loosened or removed for sufficient clearance. This will require patience and the right tools.
* Possibly the steering linkage: Depending on how much access you need, parts of the steering linkage may need to be carefully unbolted.
2. Removing the Old Oil Pan:
* Locate all bolts: Carefully locate all the oil pan bolts. They are usually around the perimeter of the pan.
* Remove bolts: Carefully remove the oil pan bolts, keeping them organized. They might be different lengths.
* Lower the oil pan: Gently lower the oil pan. There might still be some oil inside, so be prepared. The pan is likely somewhat flexible, so be careful not to damage it further as you remove it.
3. Cleaning and Preparing for the New Pan:
* Clean the mating surfaces: Thoroughly clean the engine block mating surface and the new oil pan's mating surface. Remove any old gasket material completely using a scraper. Any remaining gasket material will prevent a proper seal.
4. Installing the New Oil Pan:
* Install the new gasket: Carefully install the new oil pan gasket, ensuring it's properly seated. Some gaskets are reusable; others are not. Your manual will indicate if sealant is needed, and where to apply it.
* Install the oil pan: Carefully position the new oil pan onto the engine block, ensuring the gasket is properly aligned.
* Tighten the bolts: Tighten the oil pan bolts in a crisscross pattern, using the torque specifications provided in your repair manual. Overtightening can crack the pan.
5. Reassembly:
* Reinstall components: Carefully reinstall all components that were removed earlier (exhaust, splash shields, etc.).
* Refill with oil: Add the correct amount of new oil, as specified in your owner's manual.
* Replace oil filter: Replace the oil filter.
* Check oil level: Check the oil level using the dipstick.
6. Final Steps:
* Start the engine: Start the engine and check for leaks around the oil pan. Let the engine run for a few minutes.
* Recheck oil level: After the engine has been running for a few minutes, turn it off and let it sit for a few more minutes before checking the oil level again. Add more oil if needed.
This is a complex repair. If you are not comfortable performing this repair yourself, take your Windstar to a qualified mechanic. Incorrectly installing the oil pan can lead to serious engine damage. Remember, this is a general guideline; always refer to your vehicle's repair manual for specific instructions.
