2k1 Windstar lost AC, Odom, Speedom & flash OD Off light all at once

[Retropicker]

2001 Windstar SE Sport 198k miles.

Lost the AC and noticed the tach works, odometer is just dashes even when pushing the reset button, spedometer not moving and the OD Off light is flashing but it's shifting into OD fine.

I figure the engine computer? Where is it located?

Thanks in advance.

Frank

[Selectron]

Hi, welcome to the forum. You'll be relieved to learn that it's just a blown fuse, and it's blown because you have a leaking brake pressure switch. See the second post in this thread for more details, and if you do a forum search you'll find many more posts on the subject - it's a common problem.

[Retropicker]

Wow, Thanks, Selectron!
That was fast and accurate, I did a search but I guess your query has legs.
Thanks again.

[eddiem68]

I think the leaking pressure switch is a recall or TSB issue. I can't remember if I paid to have mine fixed when it happened.

[Retropicker]

The #10 fuse is intact but I'm heading over to the dealer to get the recalled switch replaced anyway. We'll see what happens.

[Retropicker]

The dealer replaced the harness and switch and the fuse still blows. I traced the ABS harness to the controller per the website and it's not leaking/damaged. If I unplug the new harness all lights are out, gauges work and AC blows cold.

Any suggestions other than an $85 dealer diagnostic?

Thanks

[Selectron]

If I understand correctly, you checked fuse #10 and found it to be intact. Then you visited the dealer, who replaced the switch and harness, and after that work was done, fuse #10 then blew for the first time, is that correct?

Also, were there any signs that the switch had been leaking brake fluid, or was it all dry but replaced anyway just because it was part of the recall procedure?

Edit: Also, do the gauges and A/C come back to life simply by unplugging the new harness, or have you installed a temporary jumper wire, and if so, where is that?

[Retropicker]

Selectron:
I didn't see the fuse blown before going to the dealer but I suspect that I missed see it with my glasses off, I was looking for a black spot. A/C, etc. still not working after the replacement was completed and installing the #10 made everything run fine for a few seconds before blowing. I replaced 2x to verify.

There is fluid on the remaining connections and new fitting. Whether it is from changing the switch or a previous leak I cant say. I wish I had looked prior to putting it into service.

Unpluggging the new switch without a jumper allows the odometer, speedometer (assuming, I haven't driven it) and A/C to run without blowing the #10 fuse.

Thanks

[Selectron]

I'd guess that you missed seeing the blown fuse, but it would almost certainly have been blown before going to the dealer. I would think that the recall procedure would specifically instruct the Ford techs to avoid any brake fluid spillage while changing the switch, so again I think the fluid which you can now see would almost certainly have been there beforehand too.

Ordinarily, a new switch, new section of harness, and a new fuse brings the other circuits back to life and that's the end of the matter. The problem which you now have is one that I can only remember seeing once before - it was in this thread. If you scroll down to post #10, you'll see that he ended up with exactly the same problem as you - with the switch plugged in, fuse #10 blew, but unplugging the switch allowed the fuse to remain intact and allowed the other related circuits to function normally - that's the gauges, A/C etc.

I reckon that almost certainly indicates a short-circuit in the wiring harness, caused by the brake fluid leak. There is a red/black wire which leads to the brake pressure switch, and a wire of some other (unknown) colour which leads away from it - I think the short is on that other wire. Unfortunately, we never did get to find out what the resolution to that problem was, but I suspect it would have been repair or replacement of a section of the wiring harness. I don't have a detailed wiring diagram but I do have a basic power distribution diagram which shows fuse #10 and the many circuits which it feeds - you'll see fuse #10 and the brake pressure switch at the bottom of this page.

There's a lot of information in that other thread so just a final clarification so you understand what I think is happening - the important post in that thread is post #10 - with the switch unplugged and with no jumper fitted, the fuse did not blow even though the red/black wire had 12 volts on it - but when either the switch was plugged in or a jumper was fitted and the other (unknown colour) wire then also had 12 volts applied, the fuse would blow - therefore it's that other wire which I believe has the short.

If we've now seen this problem at least twice here on the forum, I should think Ford have seen it many times and will be well aware of exactly what causes it. Given that the root cause of the problem is almost certainly fluid from that leaking switch, I wonder if, as a gesture of goodwill, they'd tell you exactly where the problem is but without charging a diagnosis fee - it might be worth asking them.