Escort/ZX2 AC problems? Read this

Paul78zephyr · #1 01-12-2006, 01:56 PM

Does the air conditioning (AC) in your 98+ Escort or ZX2 work intermittently or has it quit working altogether? Have you spent $$$ at repair garages or the Ford dealer on refrigerant recharges and/or parts replacement only to still have the problem? The cause of this problem is well documented (just do a Google search on the phrase 'Escort CCRM'), however it is not widely known in the general automotive community.

The general cause of the no/intermittent AC operation is the failure of the circuit that engages the AC compressor clutch. This clutch is electrically operated. The specific problem is the failure of a relay inside a small electronic module that is mounted in the engine compartment under the air filter housing. The module is called the Contant Control Relay Module (CCRM). The CCRM is essentially a metal housing with a single circuit board inside that has several relays on it. One relay, what Ford calls the 'WAC' relay developes a poor or broken connection (solder joint) to the circuit board causing the AC clutch energization circuit to become intermittent or fail completely. The WAC relay controls the operation of the AC compressor clutch. Ultimately the WAC relay and the entire CCRM is controlled by the main vehicle computer or Powertrain Control Module (PCM). The reason Ford uses this somewhat complex route to control the AC is it allows the PCM to sense the AC load and adjust idle and other engine parameters. It also allow the PCM to coordinate the operation of the engine electic cooling fan(s) in conjustion with AC and other load situations.

To correct this problem you can:
1. Replace the CCRM. A new CCRM will cost about $200 - $300 depending on where you buy it. It is a fairly easy part to remove and install.
2. Repair the CCRM. If you have basic automotive, mechanical, and electronics soldering skills you can remove and disassemble the CCRM, and repair the failed solder joint. This repair will cost $0 but assumes the mentioned skills and will require a drill/bits (a drillpress works even better) and an electronics type solding iron. Depending on skill the entire repair takes about an hour.

If there is interest I will go into more detail of the CCRM repair procedure.

PLEASE NOTE: There are some 'shortcut' fixes for this problem that can be found on the internet that essentially 'bypass' the CCRM/WAC relay. I do NOT recomment this approach as it prevents proper monitoring of all engine loads by the PCM.

All inquiries welcome. Please post at this thread.

Paul

AltecZX2 · #2 01-12-2006, 03:23 PM

umm the CCRM dieing is a VERY well known problem.

WAC it activates when you go full throttle on the car. It turns the A/C off to give you the full power the car can give, the problem is that the CCRM starts to think the car is at WOT at all times and does not engage the A/C

Also if you have a 98-99 ZX2 you NEED to use a 98-99 CCRM, and 99.5-2003 ZX2 HAS to use a 99.5-03 CCRM.

Paul78zephyr · #3 01-12-2006, 04:57 PM

Quote:

Originally Posted by AltecZX2

umm the CCRM dieing is a VERY well known problem.

WAC it activates when you go full throttle on the car. It turns the A/C off to give you the full power the car can give, the problem is that the CCRM starts to think the car is at WOT at all times and does not engage the A/C

Also if you have a 98-99 ZX2 you NEED to use a 98-99 CCRM, and 99.5-2003 ZX2 HAS to use a 99.5-03 CCRM.

UMM, NO!!!!!

If the problem is so 'VERY well known' then why are there so many posts at so many different Ford/Escort/ZX2 forums from people wanting to know why their AC suddenly died or is working intemittently. The purpose of my post is to give useful info to people who do not know about this problem so they can fix it or have it fixed, correctly!

Also, the WAC relay is 'on' (activated) anytime the AC is turned on. The WAC is actually DISACTIVATED by the PCM at wide open throttle. The CCRM does not 'think' at all. Its a 'dumb' electronic circuit board with electro-mechanical relays that is controlled by the PCM. But even the PCM, which does 'think' to some extent, is not the problem. The problem is with one of the solder joints beteen the WAC relay and the circuit board it is connected to in the CCRM.

I have studied the CCRM and the AC problem for some time. I have personally dissassembled several of these all having the same basic solder joint problem causing the AC to not operate or operate intermittently.

Please do not post erroneous information.

Paul

Davescort97 · #4 01-12-2006, 09:42 PM

Thanks for the post. It makes perfect sense. It was good of you to share this with us.

AltecZX2 · #5 01-13-2006, 09:09 AM

Quote:

Originally Posted by Paul78zephyr

UMM, NO!!!!!

If the problem is so 'VERY well known' then why are there so many posts at so many different Ford/Escort/ZX2 forums from people wanting to know why their AC suddenly died or is working intemittently. The purpose of my post is to give useful info to people who do not know about this problem so they can fix it or have it fixed, correctly!

Also, the WAC relay is 'on' (activated) anytime the AC is turned on. The WAC is actually DISACTIVATED by the PCM at wide open throttle. The CCRM does not 'think' at all. Its a 'dumb' electronic circuit board with electro-mechanical relays that is controlled by the PCM. But even the PCM, which does 'think' to some extent, is not the problem. The problem is with one of the solder joints beteen the WAC relay and the circuit board it is connected to in the CCRM.

I have studied the CCRM and the AC problem for some time. I have personally dissassembled several of these all having the same basic solder joint problem causing the AC to not operate or operate intermittently.

Please do not post erroneous information.

Paul

so my understanding of teh ccrm wasnt 100% ....still doesnt change that eh CCRM is WELL KNOWN PROBLEM. If you actually lok on a ZX2 site and say your AC stoped. the NUMBER 1 THING they tell you to check is the CCRM!!!

Not every escort owner is aware of all common problems, hence where ther are also like 4000 questions as to why the car idles rough.

Timtickle · #6 02-08-2006, 08:25 PM

I followed the steps and my a/c seems to be working now, thanks. I did find the bad solder job on one of the small relays. simple fix.

Thanks again,
tim

irish30 · #7 02-08-2006, 09:36 PM

Welcome to the world of made in mexico!!!!

AltecZX2 · #8 02-08-2006, 11:06 PM

made in Maxico, of japanese, european, canadian and US parts

Paul78zephyr · #9 07-21-2006, 01:54 PM

Ive been getting lots of inquires lately so I thought I put this post at the top again.

Email or PM me for info on CCRM repair (the likely cause of no AC).

Underground_Killah · #10 07-30-2006, 12:16 AM

why not post pics of you doing the repair?

4heisiam · #11 08-10-2006, 11:51 AM

Hey Paul, in may I just spen $500 to have the CCRM replaced $200 for the uint and $300 for charge and others. Now just after the 90day part warranty. It's turning on and off. Before it was comppletely dead, now it will run for a few minutes then stop. I watched and the rpm's with go up and down, like it's cycling on/off. I'm not about to shell the cash out agin for something that won't last. I know how to soilder, can you give me the details. Thanks for taking the time to share your knowledge

Paul78zephyr · #12 08-10-2006, 01:38 PM

When you say 'before' (when it was 'dead') do you mean with the old CCRM? I sent you a PM.

Paul

paqman · #13 08-19-2006, 06:16 PM

Hey, I was thinking or trying this CCRM fix for my 97 escort, but also wanted to check the other AC components before I dig in and do it. But I don't know how. I know I should check the charge, freon, whatnot, but don't know how or where any of this crap is. I've never done AC before. Do any of you know of a place online that I can find info on it? I own the Chilton's manual, but they don't tell you a lick about the AC. And I've ordered a shop repair manual on DVD that should have the info, but I wanted to get started, and it hasn't arrived yet. So any info you can give would be helpful.
Thanks,
Nate

GTP Dad · #14 08-19-2006, 07:16 PM

I just fixed mine by soldering the connection. Took less than 30 minutes to fix and works like a new one. Before spending money on a new CCRM try this fix especially if you are having trouble with intermittant or non-working AC. A whole lot cheaper than taking it to a dealer or buying a new module.

paqman · #15 08-19-2006, 08:03 PM

Quote:

Originally Posted by GTP Dad

I just fixed mine by soldering the connection. Took less than 30 minutes to fix and works like a new one. Before spending money on a new CCRM try this fix especially if you are having trouble with intermittant or non-working AC. A whole lot cheaper than taking it to a dealer or buying a new module.

Well I am going to solder the connection, I have the instructions for that, and I don't think it will take me very long, but I would like to know more about the AC system, because it is completely non-working, has not worked ever since I bought the car three years ago, and I would like to know how to check all the other AC stuff. And I want to do it myself, I don't want to take it to a shop for something I feel is easily done by myself.

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