[Arenzie]

Originally Posted by Paul78zephyr

Does the air conditioning (AC) in your 98+ Escort or ZX2 work intermittently or has it quit working altogether? Have you spent $$$ at repair garages or the Ford dealer on refrigerant recharges and/or parts replacement only to still have the problem? The cause of this problem is well documented (just do a Google search on the phrase 'Escort CCRM'), however it is not widely known in the general automotive community.

The general cause of the no/intermittent AC operation is the failure of the circuit that engages the AC compressor clutch. This clutch is electrically operated. The specific problem is the failure of a relay inside a small electronic module that is mounted in the engine compartment under the air filter housing. The module is called the Contant Control Relay Module (CCRM). The CCRM is essentially a metal housing with a single circuit board inside that has several relays on it. One relay, what Ford calls the 'WAC' relay developes a poor or broken connection (solder joint) to the circuit board causing the AC clutch energization circuit to become intermittent or fail completely. The WAC relay controls the operation of the AC compressor clutch. Ultimately the WAC relay and the entire CCRM is controlled by the main vehicle computer or Powertrain Control Module (PCM). The reason Ford uses this somewhat complex route to control the AC is it allows the PCM to sense the AC load and adjust idle and other engine parameters. It also allow the PCM to coordinate the operation of the engine electic cooling fan(s) in conjunction with AC and other load situations.

To correct this problem you can:
1. Replace the CCRM. A new CCRM will cost about $200 - $300 depending on where you buy it. It is a fairly easy part to remove and install.
2. Repair the CCRM. If you have basic automotive, mechanical, and electronics soldering skills you can remove and disassemble the CCRM, and repair the failed solder joint. This repair will cost $0 but assumes the mentioned skills and will require a drill/bits (a drillpress works even better) and an electronics type solding iron. Depending on skill the entire repair takes about an hour.

If there is interest I will go into more detail of the CCRM repair procedure.

PLEASE NOTE: There are some 'shortcut' fixes for this problem that can be found on the internet that essentially 'bypass' the CCRM/WAC relay. I do NOT recomment this approach as it prevents proper monitoring of all engine loads by the PCM.

All inquiries welcome. Please post at this thread, PM, or email me.
Paul

Please send me the steps to fix this.