95 Windstar Air Suspension problem

[vlj9r]

My 95 Windstar has been very reliable until now. Every morning the rear suspension is at the lowest position. I have to start it up and wait for it to raise itself to the normal height. I don't seem to have problems while driving it or parking it for a few hrs. It must have a leak somewhere but I don't know where to start and the Haynes Manual provides VERY little information on it. If someone could provide some documentation or website that would offer such info, I would appreciate it very much. I tried to search ebay for a Factory service manual for the 95 but only found it for the 96 model. I can't recall if there is difference between those two years. Thanks!

Jerry
Clearwater, Fl

[busboy4]

Hi Jerry
I have not had this problem yet, but was reading my manual in an attempt to help someone else. Is your amber suspension warning light on? I am guessing no. Since both sides are going flat over night either both valves are being commanded open, or the system is leaking between the compressor and the rear of the system. I would think you would hear it if the valves were commanded open - I can hear mine venting and you have probably heard yours. Normal venting is through the pressure lines and out at the compressor. Also, since both sides are flat I don't think that points to one side or the other i.e. leak in the line to the rear, not at a specific boot.
I think you could run the van to let it pump up, then shut it off and follow the lines from the compressor (left front) back listening and looking for a possible leak. You might use some soapy water in a spray bottle. According to the diagram, the air lines run under the left side of the van to the left rear and then across to the right.
If you find a leak in the air line, my manual shows a you can purchase a repair kit (#5B322) to put a splice into the nylon line.
Let us know what you find.

Good luck

[vlj9r]

Do you know where I can find diagrams for this vehicle's air suspension system? I found the air pump on the left front end, underneath the battery. It has many lines running out from underneath. I was only expecting to find one or two. I spoke to a friend of mine that owns a body shop an he is going to let me bring it in someday this week to put it on a lift. I just want to rule out tha basic stuff before I breakdown and take it to a dealer. Ive been burned by them in the past.
Thanks,

jerry
Clearwater

Originally Posted by busboy4

Hi Jerry
I have not had this problem yet, but was reading my manual in an attempt to help someone else. Is your amber suspension warning light on? I am guessing no. Since both sides are going flat over night either both valves are being commanded open, or the system is leaking between the compressor and the rear of the system. I would think you would hear it if the valves were commanded open - I can hear mine venting and you have probably heard yours. Normal venting is through the pressure lines and out at the compressor. Also, since both sides are flat I don't think that points to one side or the other i.e. leak in the line to the rear, not at a specific boot.
I think you could run the van to let it pump up, then shut it off and follow the lines from the compressor (left front) back listening and looking for a possible leak. You might use some soapy water in a spray bottle. According to the diagram, the air lines run under the left side of the van to the left rear and then across to the right.
If you find a leak in the air line, my manual shows a you can purchase a repair kit (#5B322) to put a splice into the nylon line.
Let us know what you find.

Good luck

[busboy4]

Hi Jerry,

I have a diagram in my factory manual. It is not extremely detailed, but I did look briefly at my van after I wrote to you last. The lines appear well hidden/protected along the inside of the left frame rail. The tubing is a nylon fabrication and appears off white in color. Perhaps if you start at the bags and work forward it would be easier. The lines come off of the top of each airbag and run rearward initially, then across a lateral frame piece then forward. Looking at the diagram they appear to come together just forward of the second lateral frame member when counting from the rear. This junction may be a likely leak point. From there the line moves forward along the inside of the left frame rail.

As for the lines coming off of the compressor. I think you should see two. One is the pressure line, and the other a snorkel/intake line which should route upward and rearward into the engine compartment. The pressure line is connected to the forward part of the compressor.

Now that I have written all this I see the following statement regarding the solenoid valves.which are located on top of the air springs (bags) and control air in/out of the bag. It says "because the air spring solenoid vavles are airtight to the rear air springs, (the) connecting air lines are not required to be completely airtight. The air lines only contain pressurized air during vent and compress operations". I therefore doubt a leak in the air lines since the system pressurizes o.k.. Soooooo. That leaves leaking at the solenoid valve where it meets the bag, or a signal to the solenoid valves telling them to stay open too long, venting too much air. And since your van goes flat on both sides I'm guessing the latter. The system gets input from the air suspension height sensor. It is readily visible from the rear of the van underneath. Looks like a small shock absorber. Anyway, I was going to tell you to unplug that sensor overnight and see if the van still goes flat (i.e. no signal to vent). Of course, I suppose just turning off the switch in the jack compartment over night might do the same thing. So why don't you try that just for grins. Make sure system is pumped up, then shut the vehicle down, turn off the switch and see how it looks in the morning. If it goes flat, you know the problem is not mechanical, but electrical/sensor related.

Sorry for the excessive post. Hope the info gives you a better picture to work with.

[busboy4]

Jerry, just proof read my post. My statement:

Make sure system is pumped up, then shut the vehicle down, turn off the switch and see how it looks in the morning. If it goes flat, you know the problem is not mechanical, but electrical/sensor related.

Reverse that. I think with the switch off, if it goes flat, it did so because of leakage, not because the system said to vent.

[vlj9r]

I raised it last night before going to bed and turned off the switch located in the jack compartment and this morning the rear was very low. So now I'm thinking bad solenoids/bags.

[vlj9r]

Looks like the bags are leaking a bit. Would have the info on how to replace the bags or maybe a site that would provided such info?
Thanks,
jerry

Originally Posted by busboy4

Jerry, just proof read my post. My statement:

Make sure system is pumped up, then shut the vehicle down, turn off the switch and see how it looks in the morning. If it goes flat, you know the problem is not mechanical, but electrical/sensor related.

Reverse that. I think with the switch off, if it goes flat, it did so because of leakage, not because the system said to vent.

[busboy4]

Jerry,

sorry for the slow reply. Out of town a few days. I can't suggest a website to show you bag replacement info as I know of no such. I will look into it further in my manual but it looks like a relatively difficult and touchy replacement. The solenoids on the other hand don't look to be too difficult to replace. Let me know how you are thinking of proceeding.

[vlj9r]

Now I don't know what to think. The other day I took it to work and parked it for 9 hrs. When I came back to it, the rear height was normal. I then drove it across the parking lot, parked it and shut it off. I bounced the rear bumper with my foot, when into the building for about 10mins. When I came back out the rear was low.
Here is the weird part. I took it to a friends shop and pplace it on the lift. However, the lift malfunctioned and it would not raise it more than 2 feet off the ground. (BTW, I did shut off the auto level switch) So we put it down to try on another day. Since that day, I have not seen the rear hanging low.

Strange?

jerry

Originally Posted by busboy4

Jerry,

sorry for the slow reply. Out of town a few days. I can't suggest a website to show you bag replacement info as I know of no such. I will look into it further in my manual but it looks like a relatively difficult and touchy replacement. The solenoids on the other hand don't look to be too difficult to replace. Let me know how you are thinking of proceeding.

[busboy4]

You know Jerry, it could be your vehicle height sensor. That is the shock absorber looking sensor visible on the rear of the rear axle. Perhaps your bouncing it and putting it up and down the lift exercised it toward its extremes and (for lack of a better explaination) loosened it up. I cannot necessarily reconcile that idea to your finding that the system leaked down even with the switch off, but at this point it seems very hard to pinpoint a problem. I don't think your air suspension warning light is on, so the system has not sensed a failure, but a malfunctioning, yet operating sensor might cause the intermittent problem. Just grasping here mind you, but the height sensor is what tells the solenoid valves to open/close and the system to inflate/vent. So, perhaps it is giving occasionally erroneous readings.
Keep us posted.