TSB Number:98E03 NHTSA Number:616509 TSB Date:December 1, 1998

[Freakzilla69]

Failing Component:
Power Train:Automatic Transmission:Control Module (Tcm, Pcm)Summary:
Emission recall on reprogramming powertrain control module calibration codes.

Anyone have any more information on this TSB?

[Freakzilla69]

Found some info here: http://autorepair.about.com/library/a/1i/bl785i.htm

Ford Windstar Stalling Problem
Q. Hello, I have a 1998 Ford Windstar, 3.8 liter. I have problems with it stalling when I stop at a light and leave it in drive. If I put it in NEUTRAL or PARK it is still a little rough idle but does not stall. I had the spark plugs, wires, engine coolant flushed, air filter replaced.
The computer at the local shop said I need a crankshaft position sensor changed. Did that, still not fixed. The rpm's are low in idle. Only seems to stall stopped in DRIVE like at a light or stop sign.
The service engine soon emissions light is on and the Trac off light keeps flashing. I can do 120 kilometers and it runs smooth as silk. Pull off the highway and come to a stop she starts sputtering and stalls unless I throw it into neutral!!
Any help you may have would be greatly appreciated!! I have had it looked at several times and nobody seems to be able to find the problem!!
Thanks,
Shelly
A. Ford Issued a TSB on this problem. The repair is to reprogram the Powertrain Control Module (PCM).
Article No.: 98-25-6
Date: 12/21/98
Stall During Deceleration To A Stop, Parking And/Or Coasting During Slow Speed Turns. Vehicles Equipped With 3.8 liter Engine.
LIGHT TRUCK:
1998 Windstar
This TSB article is being republished in its entirety to update the calibrations affected. CALIBRATION:
8-62J-R11, 8-62J-R12, 8-62J-R17, 8-62J-R18, 8-62J-R21, 8-62K-R11, 8-62K-R12, 8-62K-R17, 8-62K-R18, 8-62K-R21, 8-62P-R05, 8-62P-R17, 8-62P-R18, 8-620-R05, 8-620-R17, 8-620-R18, 8-62S-R11, 8-62T-R11
WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE(S). PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
ISSUE:
Some vehicles may stall during deceleration when coming to a stop, during slow speed parking maneuvers and/or coasting through slow sweeping turns. This may be caused by the Powertrain Control Module (PCM) calibration dropping the rpms too quickly during deceleration.
ACTION:
Reprogram the PCM. The revised calibration will allow the engine rpms to drop slowly during low speed maneuvers to reduce the possibility of stall. Refer to the following Service Procedure.
SERVICE PROCEDURE:

1. Perform normal diagnostics as outlined in the 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and service as required.
2. If the concern is still present, reprogram the PCM using the latest CD-ROM, Service Bay Diagnostic System (SBDS), or New Generation Star (NGS) Tester.

In fact it was an official recall. I would call your Ford Dealer and check with them. 98E03 EMISSIONS RECALL. Have the VIN number handy so they can check to see if it's been done.

Additional Information provided courtesy of AllDATA and Warranty Direct

[Freakzilla69]

I called a local dealer and they said I have no outstanding recalls "if it applied to that VIN".

Is it possible that the PCM may need to be recalibrated AGAIN?

Because I've had those exact symptoms it describes and I was almost sure that was the problem.

[Freakzilla69]

If I bought a new PCM would it have the most recent program?

It doesn't cost much more than the dealer charges for reprogramming.

[wiswind]

The problems listed in the recall...stalling under those conditions is VERY commonly caused by a sticking Idle Air Control (IAC) valve.
I would try removing it.....and spraying it out with WD-40 or Seafoam "Deep Creep".....
Hold the unit so that the fluid you spray in will run out....flushing out any dirt with it.

The IAC is a small motor driven valve that is controlled by the PCM......opening and closing a air path into the intake to control idle speed....maintaining a minimum idle speed, when your foot is not pressing down on the accellerator.

[Freakzilla69]

It doesn't stall anymore, I was hoping reprogramming would fix my lean codes.

I'm having AAMCO come pick it up tomorrow morning to replace the transmission seals. The battery was dead and I just put a warranty replacement in (Duralast Gold 850 cold cranking amps) so there were no codes, but I know they're there.

I'll ask them to test the fuel pressure under load, my main suspect is the fuel pump but pressure is fine at idle.

Vacuum pressure is good too.

I cleaned the MAF sensor not too long ago.

I've read that people say reprogramming the PCM fixed their lean codes so I was hoping mine needed it.

I dread dropping the gas tank.

My birthday was last month and my tag is expired, I have limited funds and need this fixed this weekend.

It's tough to bum rides when you have a 110 mile round trip commute.

[wiswind]

I hear you on the money.......which is why I try to suggest common solutions that are cheap.......don't want to spend big bucks on a fuel pump and find that the problem was caused by something simple that you could clean.
I would make sure that you are up on all the common routine maintenance things as well.

[Freakzilla69]

I noticed quite a jump in my fuel pressure last time I changed the fuel filter.

This was another sign to me that I could have some crud in my fuel tank, possibly clogging the pump filter.

First thing I'll do when I pick it up from AAMCO tomorrow is take it to Precision Tune and have them diagnose the fuel pressure, vacuum pressure and actual air intake.

I just rebuilt it from the block up, head gaskets even, in May, I KNOW nothing is wrong with it except maybe the fuel pressure under load.