This Haynes repair manual covers 1995-2003 Ford Windstar, 2004-2007 Ford Freestar and 2004-2007 Mercury Monterey models powered by 3.0L, 3.8L, 3.9L and 4.2L V6 engines.
Book Excerpt: 1995-2007 Ford Windstar, Freestar, Mercury Monterey Repair Manual GENERAL ENGINE OVERHAUL PROCEDURES

PISTONS/CONNECTING RODS | REMOVAL
(Refer to illustrations 14.1, 14.3, 14.4, 14.7 and 14.8) NOTE: Prior to removing the piston/connecting rod assemblies, remove the cylinder heads and oil pan by referring to the appropriate Sections in Chapter 2, Part A. On some models, there will be a sheet metal oil baffle plate attached with nuts to the main cap studs. Remove the nuts and the baffle.

1. Use your fingernail to feel if a ridge has formed at the upper limit of ring travel (about andfrac14;-inch down from the top of each cylinder). If carbon deposits or cylinder wear have produced ridges, they must be completely removed with a special tool (see illustration). Follow the manufacturer?s instructions provided with the tool. Failure to remove the ridges before attempting to remove the piston/connecting rod assemblies may result in piston breakage. NOTE: Do not let the tool cut into the ring travel area more than 1/32-inch.
2. After the cylinder ridges have been removed, turn the engine upside-down so the crankshaft is facing up.
3. Before the connecting rods are removed, check the endplay with a dial indicator or with feeler gauges (see illustration). Slide them between the first connecting rod and the crankshaft throw until the play is removed. The endplay is equal to the thickness of the feeler gauge(s). If the endplay exceeds the service limit, new connecting rods will be required. If new rods (or a new crankshaft) are installed, the endplay may fall under the specified minimum (if it does, the rods will have to be machined to restore it ? consult an automotive machine shop for advice if necessary). Repeat the procedure for the remaining connecting rods.
4. Check the connecting rods and caps for identification marks. If they aren?t plainly marked, use a small center-punch, number stamping die (see illustration), or scribe, to make the appropriate number of indentations, or marks, on each rod and end cap (1,2,3, etc., depending on the engine type and cylinder they?re associated with).
5. Loosen each of the connecting rod cap bolts «-turn at a time until they can be removed by hand.

Subject: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Ford Windstar, Freestar, Mercury Monterey service, maintenance, repair. ISBN-10: 1563927659 | ISBN-13: 9781563927652 | Haynes 36097