Quote:
Originally Posted by HIGHCOUNTRYMIKE
Check the windshield gasket. Any separation will cause a noise that will sound like the engine is going to come apart.
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Let's be clear that beginning in 1992 E-Series windshields were encapsulated meaning there is no "gasket" used. The visible surrounding molding it nothing more than a decoration.
That molding can become detached from the actual glass itself making different noises but it can be easily reattached or the entire windshield replaced using a technique that's somewhat common in the business these days.
It's possible the leading edges of the front doors can be adjusted inward to tighten the door seals against the body, perhaps use the Vent Visor devices to improve air flow off the A-Pillars.
Having now owned 4 different '97 and later E-Series vans I've never noticed or experienced any problematic noise from the windshield area. For me were I trying to fix such a customer concern I'd want to drive the van myself to hear what they're hearing. (FWIW I'm in the auto/truck glass business.)