96 ford windstar problems

* I just wanted to share my problems I'm having in my 96 windstar 3.8 first the chime/door open lights 2nd both radiator fans inop 3rd fan ac blower(inside) alway on vent (windshield) lastly ac comp not engaging.. Ok that's 4 problems I'm having..and really need help..I have been reading the site about my same problems.. But really the first thing I wanna do is the radiator fans both inop..by tomorrow I will go further about my problems. What i did for now is to make sure what are the problems so I can share it. First step I did is I checked all fuses to make sure I don't have a blown fuse from all my problems.. That includes engine compartment fuse box and the inside driver side fuse box.. So far everything was fine..I want to address the radiator first so tomorrow if I get a chance will check both fans if they really works! By directly hooking them up to the battery..I will update tomorrow what happened and will decide what will be the 3rd step...but for now any comments or suggestion will be greatly accepted! Thanks in advance!

Radiator fans should come on, at low speed, when the A/C is activated...... and STAY on.
Very common, radiator fan low speed dropping resistor.
This is mounted on the metal bumper......roughly below the passenger side headlight.
It has a white ceramic body.
It is in my pictures....which the link in my signature take you to.

The Constan Control Relay Module (CCRM) contains the relays for the fans, fuel pump, and A/C compressor.
The PCM tells the fans to turn on.......based upon the coolant temperature or the A/C being on.
The CCRM is shown in my pictures.....mounted on the radiator support on the driver's side.
It is called by several names on part store parts list.....Computer relay, control relay, etc

The door chim and internior lights being on.......generally caused by a door sensor.
On the front doors, the door sensor is mounted to the latch, inside the door.
I have a picture of it in my pictures.

The air always going to the windshield......defrost is caused by a lack of vaccum to the controls.
The dash switch controls the vaccum application to vaccum actuators that move doors in the ducting directing the air to the various places.
When there is NO vaccum, then the default position is all air to the windshield.
The vaccum comes from the back side of the upper intake manifold on the motor......and comes through the firewall into the passenger compartment.
If you look up under the dashboard on the passenger side.....you will see the "bulbs" with the vaccum lines going to them.
There is a resevoir on the passenger side inner fender....near the firewall that holds vaccum to keep the doors in position when the motor is not running.
You will need to follow the vaccum lines to figure out where one is disconnected or damaged.

A/C compressor not engaging......CCRM can also cause it......low refrigerant.......(leak) or cycling switch....
I show the switches (high pressure and cycling) in my pictures also.

well nothin has been done. it was rainy and windy day today here in chicago. I will again attempt tomorrow.
@wiswind..thanks for the fast answers!! your making me too excited to work on my windstar. here are more questions and updates on my problems..

as i recall last year..the radiator fan (main) will work when the engine gets really hot (over the normal temp) then the ac fan will work when i turn on the ac. (im assuming low speed not functioning?) .. so i decided to just let go. it will work fine! thats what i had in mind! i said that because when i took it to my mechanic he cant find the problem? i actually have to change the thermostat assuming thats the problem.. but thats not the problem at all.. now a year had past..
turn engine on, let it run, wait for a few minutes viola!! temp gauge is goin up!! over the normal no fan will turn on!! then i tried the a/c if the ac fan will turn on...!! no ac engaging, no cold air coming out and the fan also didnt work!! so both fans are inop!! now im wondering coz when i take the windstar for a drive it will not overheat on me as long as im continously moving.. the faster the better!.. so im not sure if the high speed mode works? on both fans? or im just lucky?? i have to check on that and update you! so far thats wer i am... diagnosing.. i really hope we get the sunshine so i can start working on it. i dont have enclosed garage.

update: just found out the wire that connects to the ceramic resistor was broken off it was corroded. will order a new one if i find a part number and place where i can order it. in case if this is just one of the problems my next step would be replacing the ccrm? how much would this go for? and if the final problem was the PCM would the PCM should be sending a signal that will turn on my check engine light?

update 2: as for the a/c vents. i traced the line (vacuum line) and found an orange tube going to the main control/switches, i cant find the one that goes thru the firewall? anymore clues? thanks!

Most likely you have high speed fan....but no low speed......the broken resistor will prevent low speed operation.
I bought mine through a FORD dealership.



The resevoir for the vaccum in the engine compartment is on the inner fender.....slightly visible back of the A/C accumulator tank in this picture.
You could try to see if you can follow vaccum lines from there......
http://inlinethumb58.webshots.com/24185/2077761460011220610S600x600Q85.jpg (http://rides.webshots.com/photo/2077761460011220610tpjsMq)

i did a little work on the windstar.. i took out the dropping resistor and ordered a new one. i also tested both fans if will work in high speed which it did! good news for me! done with that for now til the part show up.

i went to my next problem which is the air on defrost mode only. i checked every line if there is any loose hose, i tried to follow the line but its very difficult (behind the black plastic by the firewall) no luck! just want to make sure im tracing the right line..my line is red in color and i saw a black too so i followed both and they feel and looked ok? is there an easier way or even a better way to access those lines? my plan is to stick my camera inside and take a picture coz i cant see the connections behind the black plastic i just inserted my arms and try to feel for any loose connections..

the other problems will be taken care of later(door/chime)

i will have the ac freon check if i need a charge.. coz it was working fine last summer. it just stop working now.

For the air going to the windshield......with the motor running at idle.....I would pull a line and put my finger over the end......and see if there is vaccum.
If there is....then you are OK up to that point.

I don't recall the color of the lines.......and I just recently sold my windstar, so I don't have it to look at.
The picture in my other post....I can see gray for the IMRC and a red one that looks like it is heading over toward the resevoir.

If you check in the pictures that the link in my signature takes you to.....you may find some pictures that may help you with the various projects involved in keeping a older vehicle in good shape.

This is a picture of the upper intake manifold......looking from the bottom.......the throttle body would be mounted on the right side......
You can see most of the many vaccum line connection points on the back of it.
To add to the confusion, many connections branch off to multiple places.

http://inlinethumb29.webshots.com/7068/1201992874011220610S600x600Q85.jpg (http://rides.webshots.com/photo/1201992874011220610iKENkQ)

As far as the A/C freon charge.....sadly, if it is low.......it went someplace.
I only had 1 leak develop over the life of mine.......but it was the evaporator coil.....which is the most labor intensive ($$$) part on the A/C system.
In Wisconsin, the DIYer cannot buy freon, R-134, etc......as it requires a license to buy.
A check to see if the freon is OK......if it is, then maybe one of the switches is acting up....which are shown in the picture in my other post.