Help!!! The Ac Has A Vent Problem It Blows Thru Defrost Then Floor Then Vent. Help!

[stuartnh]

I do agree with you that it's a bad idea to use my garage’s air compressor and I was worried about trying it without asking and seeing some feedback first, thanks for the warning.

But also thanks for the great idea about using another cars vacuum for a source of vacuum, which would be a very easy thing to try with just some hose.

If it makes the Windstar's vents work correctly when hooking up to the vacuum line at the engine that would mean I have no vacuum at the engine and I could compare it to my 01 Sport Trac and focus in on upper intake manifold gaskets maybe.

If it does not work maybe then I would have a small chance of listening for a vacuum leak with another car running and being quieter under the hood & dash of this car.

I will keep you updated.

[stuartnh]

I used another auto's vacuum with a 10 foot vacuum hose and the vents on the Windstar work just fine. On the Windstar, two lines (one small and one large) go into a 2 to 1 female rubber Ford OEM adapter right at the motor and I think it maybe the problem. I need to check the vacuum at the motor and see if it’s the same or at least close to the other auto I used as a test and then maybe replace the OEM adapter with a new one and see??? I will let you know, but I am close!!!

[12Ounce]

Good to hear that you are "hot on the trail"!

I will be surprised if it turns out to be the upper manifold gaskets .... I don't believe that they can leak that large amount of air without setting off a code. I'm inclined to suspect a clogged/broken tube/fitting or some restriction somewhere.

[stuartnh]

Today I ran a vacuum hose from my Sport Trac to the Windstar's vacuum hose right where the hose comes off at the motor, with the Sport Trac's engine running and the Windstar's engine off and key on only the vents worked correctly. The vacuum on the Sport Trac was 17 and the Windstar's was 15 on my gage and it took only 5 to move the deflectors in the Windstar under the dash with the hand pump.
At the engine on the Windstar there are two different size vacuum lines going in to a rubber adapter and then that pushes onto the engine. I plugged the one going towards the brake booster and plugged only the one vacuum line on the Windstar at the same location I used with the Sport Trac, the dame thing still did not work, I guess that rules out the second vacuum line going towards the booster being a problem.
Monday morning I will go the the Ford dealer and buy a new 2 into 1 Ford OEM rubber adapter and I think it will fix it. The lines go into it and seem like a good fit but the end that goes onto the engine seems loose, I hope this is the solution. I will update after Monday. Tomorrow I may try spraying some water at the rubber adapter to see if the engine runs worst when it's sucking up some water!

[stuartnh]

Water stalled the engine today. I sprayed water at the vacuum connection area by the cylinder head.
Tomorrow I will get a new fitting and let you know if its all better, stay tuned...

[stuartnh]

Its all fixed, the vacuum line 2 in to one at the motor was leaking, a new one fixed it. Thanks for eveyones help with the ideas and stoping me from trying things that would have caused more issues. Thanks again

[stuartnh]

I thought I had it fixed, here is the real fix...

Under the hood at the passenger side of the motor in the back is where the adapter is. I thought this was the problem but it turned out to be the other end of the red hard plastic tubing. Follow the red tubing up to yet another adapter and that is where mine was cracked, the red hose was cracked right at the rubber 90 and it was only cracked half way through.
The rubber 90 pushes up onto a nipple that points straight down from the underside of the part where you would find the wiper linkage under the hood on the passenger side. It's hard to explain, but follow the red vacuum hose to that 90 and it changes to black at that point with yet another adapter that could cause issues. I pulled my hose and the 90 off at the nipple that points straight down by accident at the other end of the red hard tubing (not the motor end) and until I looked at another Windstar I could not find a nipple to slide it back onto. If it's on and I am sure yours still is if you have not messed with it yet you will be able to find it, I would look there first if your having this problem. It's a poor design and good luck.

[busboy4]

Hey Stuart

Glad you finally found it. I applaud your patience as you just saved yourself a small fortune, unless your local mech. is smart and honest. My professional aircraft mechanic father always called something like this "a major malfunction of a minor component".
I agree.