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Old 07-21-2006, 02:02 PM   #1
Paul78zephyr
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AC not working on your Escort or ZX2? Read this.

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
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Old 09-09-2009, 11:57 AM   #2
bvoccs
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Re: AC not working on your Escort or ZX2? Read this.

I am interested in more information on how to repair the solder joint inside the ccrm for a 99 escort zx2. Pease send me any info you have. thanks in advance!
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Old 05-28-2010, 01:06 PM   #3
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Re: AC not working on your Escort or ZX2? Read this.

looking for details on the location of the ccrm on my 2003 ford zx2..
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Old 05-28-2010, 08:19 PM   #4
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Re: AC not working on your Escort or ZX2? Read this.

Welcome to Automotive Forums!

The CCRM should be in front of the strut tower on the driver's side of the car. If you look closely you will see it under the air filter housing. It's a small box with a lot of wires going into it.
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Old 05-30-2010, 12:17 AM   #5
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Re: AC not working on your Escort or ZX2? Read this.

I have the same problem. 1998 Ford Escort SE Wagon. It just quit one day last summer after being started up in the heat. It blows air, just not cold air. The heat works, as does everything else... just no AC. I was thinking that the compressor was bad, but now this seems like the most likely culprit. Are there any directions or guides online for how to fix this/diagnose it? I've just gotten into mechanics, so although I may know some stuff, I couldn't do a job like this flying solo if my life depended on it.
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Old 05-03-2012, 07:19 PM   #6
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Re: AC not working on your Escort or ZX2? Read this.

I need the instructions for fixing this my self.
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Old 05-03-2012, 07:32 PM   #7
Arenzie
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Re: AC not working on your Escort or ZX2? Read this.

Quote:
Originally Posted by Paul78zephyr View Post
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.
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Old 08-06-2012, 10:33 AM   #8
ferncreekjeep
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Re: AC not working on your Escort or ZX2? Read this.

I made sure the compressor and clutch/coil were all operational, then I opened up the CCRM. There was no discoloration or cracks, just minor corrosion on most of the board. I replaced it with a rebuilt one from O'Reilly's for $80. The compressor kicked on and I was able to recharge the AC system. It was blowing cold and working great. Then I turned the car off and restarted. Now the compressor won't come back on, just like before. Do I have another bad CCRM/WAC Relay? Or am I missing something else? Did something short the new/rebuilt CCRM? Has anyone else had this problem?
Thanks!
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Old 03-03-2013, 05:50 AM   #9
danim775
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Re: AC not working on your Escort or ZX2? Read this.

Paul,

Please please send this me this repair info! Thank you!

Dani
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Old 03-03-2013, 10:37 AM   #10
brcidd
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Re: AC not working on your Escort or ZX2? Read this.

You can bypass it fine with all the same controls- if you do it right- use the same four input/output wires the CCRM uses and a bosch style external relay- no need to open up CCRM- just solder four wires and now you have an exact parallel circuit. PCM still has complete control, exactly as before. Just grab a wiring diagram and create your paralle circuit- I've done 5 or 6 this way with no issues and no comebacks..
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Old 06-08-2014, 08:30 PM   #11
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Re: AC not working on your Escort or ZX2? Read this.

Hi Paul,

Could you please email more info about removing/replacing the CCRM? Also, how did you know for sure that the problem was the CCRM? I've had a mechanic tell me that the problem is my condenser, but from what you've described, I suspect the problem my actually be the CCRM. Thanks!!
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Old 09-22-2014, 10:11 PM   #12
ironmike56
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Re: AC not working on your Escort or ZX2? Read this.

Hello Paul,

Please send me the info regarding repairing the CCRM solder joints.

Thank you for creating this post.
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