2001 Ford Windstar Air Vents not working

Tiny
PANIOLO1
  • MEMBER
  • 2001 FORD WINDSTAR
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 155,000 MILES
Using AC or Heat, only the windshield defrost vents work no matter what vent selection I use. The fuse and relay for the air blend motor are fine. It appears that the actuators are vacuum controlled. Where is the source of vacuum? Could the selector switch be bad?
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Thursday, February 19th, 2009 AT 6:07 PM

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Tiny
DAVE H
  • EXPERT
TEST D: IMPROPER/ERRATIC AIRFLOW FROM OUTLETS
Start engine and let idle. Set blower to high speed. Turn climate control switch to each airflow position and check airflow at outlets at idle and under engine load. If there is airflow only from defrost outlets at each switch position, go to next step. If airflow is from defrost outlets at all settings only under engine load, go to step 19 . If airflow is incorrect under one or more conditions, go to step 13 . If airflow is correct under all conditions, return to SYMPTOM INDEX table.
Turn ignition switch to OFF position. Check for disconnected vacuum supply hose between intake manifold and A/C vacuum reservoir. If hose is disconnected, reconnect hose and retest system. If hose is properly connected, go to next step.
Disconnect vacuum supply hose. Attach vacuum tester to end, and test for leaks. Apply vacuum and observe gauge. If vacuum leak is present, repair or replace hose. Retest system. If hose does not leak, go to next step.
Start engine and let idle. Check vacuum check valve for correct installation by removing reservoir hose from check valve, one at a time. Feel for vacuum. Reconnect hose. Disconnect vacuum check valve-to-control panel assembly Black supply hose. Feel for vacuum. Reconnect hose. If vacuum is available at both ports, go to step 6 . If vacuum is not available at either or both ports, go to next step.
Turn ignition switch to OFF position. Disconnect vacuum check valve. Inspect check valve for obstruction and correct airflow. Airflow should be in direction marked VAC (vacuum). If valve is plugged or restricted, replace valve. Retest system. If valve is okay, go to next step.
Turn ignition switch to OFF position. Disconnect all 3 vacuum hoses from vacuum check valve. With a "T" fitting and 2 hoses, attach check valve to vacuum pump. Apply 15 in. Hg of vacuum and observe vacuum gauge. If vacuum leaks down more than 1 in. Hg per minute, remove check valve and plug vacuum hoses. Apply 15 in. Hg of vacuum to ensure tester and hoses are not cause of leak. If check valve loses more than 1 in. Hg vacuum per minute, replace vacuum check valve. Retest system. If vacuum does not leak down more than 1 in. Hg per minute, install vacuum check valve, hoses and go to next step.
Disconnect vacuum reservoir tank. Connect vacuum tester to vacuum reservoir tank. Apply vacuum and check for leak down. If vacuum reservoir tank leaks, replace vacuum reservoir tank. Retest system. If vacuum reservoir tank does not leak, go to next step.
Remove A/C-heater control assembly. Disconnect and plug Black supply hose at damper door switch. Attach vacuum tester and apply vacuum to Black supply hose to check for leaks. If Black supply hose leaks, replace hose and retest system. If Black supply hose does not leak, remove plug, connect vacuum hose, and go to next step.
Disconnect vacuum harness at in-line, multiple connector near damper door switch. Plug all vacuum hoses except Black supply hose. Select each position on climate control switch while applying 15 in. Hg of vacuum to Black hose. If vacuum drop exceeds 1 in. Hg per minute, note position(s) where vacuum leak occurs, and go to next step. If system holds vacuum, go to step 11 .
Remove vacuum harness from climate control switch. Connect vacuum tester to control supply port and plug control port that indicated leak in previous step. Select appropriate function position and apply 15 in. Hg of vacuum. Vacuum leak down should not exceed 0.5 in. Hg per minute. If vacuum leak down exceeds specified rate, replace climate control switch. Retest system. If leak down does not exceed specified rate, go to next step.
Disconnect mode selector switch vacuum supply hose. Connect vacuum tester to supply hose and try to pull a vacuum. If vacuum can be pulled, hose is plugged or restricted. Replace hose and retest system. If no vacuum can be pulled, connect supply hose and go to step 15 .
Plug one end of suspect vacuum hose, as noted in step 9 . Attach vacuum tester to other end and apply 15 in. Hg of vacuum. If there is leakage at vacuum jumper harness connector, repair or replace vacuum jumper harness. Retest system. If no leakage is noted, check connection of vacuum harness to climate control switch. Repair as needed. Retest system.
Turn ignition switch to OFF position. If airflow system functioned properly prior to current complaint, go to step 16 . If airflow system did not function properly in the past, go to next step.
Individually check each vacuum hose. Connect vacuum tester to each hose and try to pull vacuum. If vacuum can be pulled, hose is plugged or restricted. If hose is plugged or restricted, replace vacuum hose and retest system. If vacuum cannot be pulled, go to next step.
Compare vacuum hose color in vacuum harness with each connector on climate control switch vacuum connector. See VACUUM DIAGRAMS . If hose colors of vacuum harness and connector colors match, go to next step. If hose colors of vacuum harness do not match, replace vacuum harness. Retest system.
Check A/C vacuum circuit for pinched or kinked vacuum hose(s). If any hose is pinched or kinked, reposition or replace hose and retest system. If hoses are okay, go to next step.
Check each vacuum hose to ensure it is properly attached at all connections. See VACUUM DIAGRAMS . If any vacuum hose is disconnected, reconnect hose and retest system. If hoses are properly connected, go to next step.
If any hose was suspect of leaks in any prior checks, disconnect suspect hose, plug one end and attach vacuum tester to other end. Apply vacuum to hose and check for leaks. If leak exists, repair or replace hose. Retest system. If no leaks exist, go to next step.
Disconnect hose from vacuum control motor. Apply 15 in. Hg of vacuum to vacuum control motor and check for leaks. If vacuum drop exceeds 0.5 in. Hg per minute, replace vacuum control motor and retest system. If vacuum drop is within limits, connect vacuum control motor hose, and go to next step.
Turn ignition switch to OFF position. Check attachment of vacuum control motor to damper door. If motor arm is properly attached to damper door, service damper door for binding and retest system. If motor arm is not properly attached to damper door, connect motor arm and retest system.


http://www.2carpros.com/forum/automotive_pictures/266999_vac_8.jpg

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Thursday, February 19th, 2009 AT 6:20 PM

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