1999 Ford Windstar

Engine Performance problem
1999 Ford Windstar 6 cyl Front Wheel Drive Automatic 200000 miles

I have a 99 windstar. It will die while driving as if the ignition key was turned off. It did bring on the check engine light with a P0320 code. It will start up and run again after I wait 2-3 hrs for the whole engine to cool down, then it might die again after 5 miles of driving. I erased the code after I installed a new crankshaft sensor. It ran fine for a day then it all happened over again without bringing on the code this time. Next I changed the coil pack. It ran again, but now is still dying out while driving down the road and won't start unless it is allowed to cool down for 2-3 hours. The code has not came back after the first time.
December 17, 2008.

Of course your doing these check's whilst the vehicle is working correctly? Or cool down? It could be we need to take readings when the fault has actually just occurred? When it will not start again? If it is the pcm going wrong we should not get any readings at all when fault first occurs?. Also if there are no fault codes recorded. Why? Unless it is the PCM not working when hot and the fault occurs? Do you agree/disagree?

Dave H
Dec 19, 2008.
I have marked the PCM relay ? it is in underhood fuse/relay box

Dave H
Dec 19, 2008.
Well, I called the dealer and they cannot read out the PCM off the car. They want me to bring in the car of course. After I checked the CKP sensor for voltage and ran some of the checks and put it all together, the van was all completely cold and it would only crank and not start. It leads me to think this problem is intermit and not related to heat at all just a coincidence. What else besides the CKP wiring and PCM could bring on this code after I already changed the coilpack too.

Dec 19, 2008.
I wonder what the PCM relay does? I saw the picture of it. I saw someone recommend a website that sells relays for cheap. Any recommendations on where to get the relay? First we have to research what it does.

Dec 19, 2008.
I tried to start the van up after having it sit for 2 days and while everything is cold it won't start. This is definitly intermit. I ran the scanner and no codes. The Mil lamp is not on while I am cranking over. I pulled the PCM out. The number of the PCM is XF2F-12A650-MF. LWA5 is on there also. The PCM relay part # is FOAB-14B192-AA.

Dec 19, 2008.
I don't have a listing for the relay? I have a price of $394 for the PCM.? Does the MIL come on with the key ON not cranking? Is the scanner linking and coming up with no codes.? I still have my doubt's this is a PCM fault?

Dave H
Dec 19, 2008.
The scanner is linking up and coming up with no codes at all. I know the MIL light comes on when the key is turned to the on position. Can you tell me the purpose of the PCM relay? What makes you doubt it is the PCM?

Dec 20, 2008.
I found this TSB. It may/may not be of help. I'm not sure of the PCM being at fault because we seem to be getting good responses to the test's you perfrormed and we are still getting MIL @ KOEO. The light goes off @ cranking like it should and we are getting no codes. But now you have cranked it over a few times. With a no start. I would expect some sort of code to be popping up. It should be registering a fault with no start @ crank? I'm looking into the relay now?

Reference Number(s): 06-14-10, Date of Issue: July 24, 2006
FORD: 1999-2003 Windstar; 2004-2007 Freestar
MERCURY: 2004-2007 Monterey
Superceded Bulletin(s): 05-23-7, Date of Issue: November 28, 2005
Related Ref Number(s): 05-23-7, 06-14-10
NOTE: This article supersedes TSB 05-23-7 to update the Service Procedure and model years.

Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts / engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area.
During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure.
Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Fig. 1 )

Dave H
Dec 20, 2008.
I think it has something to do with WATER INTRUSION to the PCM. This discrepancy happened all after a big series of rain storms here in hawaii and driving home in a heavy rain. When I took the PCM out the connection was a little " sweaty" looking. If the connection is all dry it should start up now, but maybe the PCM got damaged now. Is the repair procedure longer than just remove the pcm cover and inspect? How do I look at the transaxle vent? I found an ebay ECU exchange for $150 and he flashes all the updated calibration info on the new PCM. I think that would be a wise thing to do, but can you also help me locate the sources of water intrusion through the cowl? We are getting there. Baby steps.

Dec 20, 2008.
Let me know which pictures you require ?

Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Fig. 1 )
Fig. 1: PCM Connector
Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Fig. 2 ) If sealant is interfering with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead.
Fig. 2: Body Sealant On Bulkhead
Remove the wiper pivot arm. (Fig. 3 )
Release pivot arm nut cover.
Remove the pivot arm nut.
Remove the pivot arm.
Fig. 3: Removing Wiper Pivot Arm
Remove the screws. (Fig. 4 )
Fig. 4: Removing Wiper Pivot Arm
Release the clips.
Remove the windshield wiper hose.
Remove the upper cowl panel grille.
Disconnect the electrical connector. (Fig. 5 )
Fig. 5: Disconnecting Electrical Connector
Remove the lower cowl panel assembly. (Fig. 6 )
Remove the ten (10) bolts.
Remove the lower cowl panel assembly.
Fig. 6: Removing Lower Cowl Panel Assembly
Obtain two (2) PVC soft foam adhesive strips (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900).
Cut both of the PVC soft foam adhesive strips in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Fig. 7 )
Fig. 7: Cutting PVC Soft Foam Adhesive Strip
Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM.
Place two (2) of the cut pieces of the PVC soft foam adhesive strips on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Fig. 8 )
Fig. 8: Adhesive Strips On Body Surface Over Transaxle Area
Place the other two cut pieces of the PVC soft foam adhesive strips on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Fig. 9 )
Fig. 9: Adhesive Strips On Body Surface Over PCM Area
Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Fig. 10 )
Fig. 10: Rubber Plugs And Plastic Clip Locations
Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Fig. 11 )
Fig. 11: Rubber Plugs On Bottom Of Cowl Sheet Metal
Install the lower cowl panel and 10 retaining bolts. (Fig. 12 )
Fig. 12: Lower Cowl Panel And Retaining Bolts
Connect the electrical connector. (Fig. 13 )
Fig. 13: Disconnecting Electrical Connector
Install the upper cowl panel grille.
Install the windshield wiper hose.
Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Fig. 14 )
Fig. 14: Removing Upper Cowl Panel Screws
Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Fig. 15 )
Fig. 15: Sealing Front Seam Between Upper And Lower Cowl
Install wiper pivot arms. (Fig. 16 )

Fig. 16: Installing Wiper Pivot Arms
Check the wiper pivot arm adjustment.
Part NumberPart Name
N806322-SPushpin Screw/Rivet (4 per repair)
TA-32Clear Silicone Rubber
TA-26Threadlock 262
164-R4901PVC Soft Foam Adhesive Strips - Rotunda Part (2 per repair)

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.
061410A2004-2007 Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A)1.0 Hr.
MT061410Claim Additional Labor Required As Actual Time Or Use SLTS Operation If AvailableActual Time

Dave H
Dec 20, 2008.