Not sure where to start? Take a look at our Job of the Month. This month we show you how to replace a head gasket in a 1996 – 2002 Ford Windstar.

This job is a little more involved, but our step by step guide will walk you through the process of removing and replacing your Windstar’s head gasket and you’ll be back on the road in no time.

Make Safety Your Top Priority

Every vehicle is different, so when it comes to maintenance and repairs, always follow the vehicle's owner's manual. Don't work with a Philips when it calls for flat. Substituting tools can compromise your safety or your vehicle's performance.

Safety should be your number one priority, so don't smoke, drink alcoholic beverages, or wear a necktie. And watch out for hot objects, sharp instruments, hazardous materials and other potential safety hazards in and around your workspace.

And finally, when the fun turns to frustration or if the job requires specialized knowledge beyond your abilities, seek the assistance of a Parts Pro, professional mechanic or installer. The last thing we want is someone getting hurt.

How to Remove a Head Gasket
	Disconnect the negative battery cable.
	Drain the cooling system.
	Remove the air inlet tube between the throttle body and air cleaner.
	Remove the serpentine belt.
	Remove the upper and lower intake manifolds.
	Remove the power steering pump
	Remove the alternator.
	Remove the idler pulley
	Unbolt the A/C compressor, and place to the side out of the way, with all hoses still attached. You may need to secure the compressor with mechanics wire to hold it out of the way.
	Remove the valve covers.
	Loosen rocker arm bolts, and pivot rocker arms from push rods. Note: Mark component location for reassembly reference.
	Remove cylinder head bolts, and throw away. Note: Do not reuse old cylinder head bolts!!!!
	Remove cylinder head and gasket. Note: Inspect cylinder head for cracks or warpage. Have the cylinder head machined if warpage exceeds specification. Check cylinder block for warpage, if warpage exceeds specification have the block machined.
	Clean cylinder head and block of any gasket residue. Tip: If the gasket is stuck to the block or head securely first spray with gasket remover and let sit. Then use a gasket scrapper to remove the gasket residue.
	Clean the cylinder head bolt holes.

How to Install a Head Gasket
	Install the new head gasket.
	Install the cylinder head.
	Install NEW cylinder head bolts, and tighten to specification in sequence.
	Coat the ends of the push rods with engine assembly lubricant.
	Install in original position.
	Rotate crankshaft until the push rod is fully downward, and the valve lifter is on the base circle of the camshaft.
	Install rocker arm on push rod, and tighten bolt to specified torque.
	Install valve covers, and tighten bolts to specified torque.
	Re-bolt A/C compressor to specified torque.
	Install idler pulley
	Install alternator.
	Install power steering pump.
	Install upper & lower intake manifold.
	Install serpentine belt. (inspect old belt, replace with new if required)
	Install air inlet tube between throttle body and air cleaner.
	Refill the cooling system.
	Connect the negative battery cable.

See you local PartSource for FREE print out instructions including specified torque specs, and figures.