Any Ford Windstar Silent Recalls or Campaigns?

Have major repairs on my 1999 Windstar w/ 3.8L and OD Auto. Wondering if anyone knows of any Ford silent recalls or campaigns to fix the following problems. I understand they are common:

1. Flashing tranny OD light being caused by faulty forward clutch and high pump pressure. Shop wants to rebuild for about $1800, but I want to know what Ford is doing about this if anything.

2. Heater A/C blend door and box. Need to replace actuator and box, and this door is a common breakage problem. No heat to front. Again, shop wants almost $1000 to get into the dash and replace this (includes box, which isn't cheap).

1. The forward clutch issue is a common problem. You can try to push the issue, but you problem won't get very far considering the age of your vehicle. Mine had the same problem at 28k, thankfully still under warrenty. My understanding is that Ford redesigned the forward clutch mechanism. So far the new transmission has 50k and no trouble.

2. DO NOT REPLACE THE BOX AS THE FIRST OPTION!
Replacing the entire box is the first thing listed in service manuals when the blend door isn't workiing. However there are a couple of other less expensive things to check: 1) The blend door servo motor may be broken. The part is easier to access and a lot less expensive to buy (about $50). The plastic gears in mine were shredded. And 2) The D-shaped fitting that the servo motor fits in may now be round. If you are willing to do a little work, then check out http://www.automotivehelper.com/topic298619.htm

[QUOTE=akdelikat]2. DO NOT REPLACE THE BOX AS THE FIRST OPTION!
Replacing the entire box is the first thing listed in service manuals when the blend door isn't workiing.

Thanks for the reply. I didn't elaborate, but this blend door has already been fixed once using the glue and pray method, which lasted for 9 months or so. This time the door bound up, the actuator kept pushing, and it blew a hole right through the end of the blend box. New blend box isn't TOO bad, but the labor to get in there is awful. As usual, engineers are designing things for the assembly line, and not the repair shop. I know. I'm an engineer.

2. DO NOT REPLACE THE BOX AS THE FIRST OPTION!
Replacing the entire box is the first thing listed in service manuals when the blend door isn't workiing.

Thanks for the reply. I didn't elaborate, but this blend door has already been fixed once using the glue and pray method, which lasted for 9 months or so. This time the door bound up, the actuator kept pushing, and it blew a hole right through the end of the blend box. New blend box isn't TOO bad, but the labor to get in there is awful. As usual, engineers are designing things for the assembly line, and not the repair shop. I know. I'm an engineer.


Please tell me you are one of those rare engineers with mechanical ability... order the part and replace it yourself... a day's work.

gbillman
When you write "entire box" are you referring to the plenum that goes the full width of the car?

If so, that would be more than a one day job for this old man...dumping/refilling coolant system...dumping/refilling ac system...as well as all the hardware work.

OK, so I'm slow!

By the way, one thing that has caused some blend doors to hang up is one of the forward mounting studs on the plenum not being properly inserted through matching hole in firewall.

My blend door broke because it was (temperature?) warped and was straining at the pivot area when it reached either of its travel stops. I ended up cutting into the plenum with a rotary tool... repairing/replacing the blend door. A lot easier than replacing the plenum.