2003 Ford Windstar BaseFACTORY OEM SERVICE PROCEDURE

Chain Cover: Assembly

  1. Measure the distance that the center bi-metal element pin protrudes from the chain cover.
    Fig 1: Measuring Distance That Center Bimetal Element Pin Protrudes From Chain Cover
    G01308751Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the bi-metal element.
    1. Position the bi-metal strip onto the end of the pin.
    2. Install the special tool under the bi-metal element.
    3. Tap the retaining collar onto the pin until it seats against the special tool edge.
    Fig 2: Installing Bimetal Element
    G01308752Courtesy of FORD MOTOR CO.
  3. Using the special tool install the bi-metal element.
    1. Position the bi-metal strip onto the end of the pin.
    2. Install the special tool under the bi-metal element.
    3. Tap the retaining collar onto the pin until it seats against the special tool edge.
    Fig 3: Installing Bimetal Element
    G01308753Courtesy of FORD MOTOR CO.
  4. Remove the slotted end of the bi-metal element and install the thermostat plate over the end and middle pins.
    Fig 4: Installing Thermostat Plate Over End And Middle Pins
    G01308754Courtesy of FORD MOTOR CO.
  5. Install the slotted end of the bi-metal element under the retaining ring.
    Fig 5: Installing Slotted End Of Bimetal Element Under Retaining Ring
    G01308755Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not allow the pistons to cock in their bores or damage to the seals may result.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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