96 windstar cooling fan issues

[martin tyree]

Hi,
96 3.8 windstar couple of problems. cooling fans work when switched to a/c. [replaced burned out dropping fan resistor] but no cooling fans work in regular normal stop and go driving on xpressway driving conditions. I say this as I watch the gage start to climb. also can someone please explain a little more in depth what the ccrm relay does as far as what it controls
thanks, martin

[tripletdaddy]

To be clear, the radiator fans DO NOT come on with just driving, idling at a stop or parked when engine gets hot? Then I would suggest pulling the TWO wire connector off the engine coolant temperature (ECT) sensor, which is found next to the thermostat housing, upper radiator hose, heater and bypass hoses, and the fuel pressure regulator, which is a shiny little clam like can with a tiny black hose going to the top of it. Removine this TWO wire connector while the engine is on will cause the fans to come on like the ac turns them on. If they don't come on, then we may consider the CCRM or the wiring involved. If they do come on, there is a pretty good chance the ECT is bad. If you want you can do a resistance test or simply replace it if you want to be confident it is not that anymore, as they are cheap, $5, be sure to get brass not plastic sensor.

The CCRM is the constant control relay module. It is found mounted by the battery, black, the size of a deck of cards and has a 24 pin/wire connection. It controls the fuel pump relay, the low speed fan control relay, the high speed fan control relay, and the air conditioning clutch control relay. Unfortunately, if one part of it goes bad, you have to replace the whole thing. Ford has since made these as separate controls. It is testable. Does your ac work? If not, maybe the two problems are related. The CCRM is a bit more expensive, so I myself would not rush to thinking it is bad. At the very least, it may be worth your time to visit Autozone.com to look at costs of these "electrical" items and also for the location and testing of said items. I use a Haynes manual, so I am not sure how good AZ's testing section is. If you want to test things and need more help, ask.

[martin tyree]

thanks for the info .i also noticed that my a/c is not working. I will get back to you folks after the weekend and give you an update.

[tartersauce]

Originally Posted by martin tyree

thanks for the info .i also noticed that my a/c is not working. I will get back to you folks after the weekend and give you an update.

Next to your battery the fuses are ther in a box for your rad fans. Ive seen one fan get stuck and blow the fuse to the relays.
Simple check, make sure the fans spin when pushed and theres no noise when turning.. DONT HAVE THE KEY ON Or the Engine HOT when you check this!! If it still works and just stuck, It will take off as soon as your push on the blade..

[wiswind]

Aside from the fuses......the signal to activate the radiator fan High and Low speed relays comes directly from the PCM.
The fans will be ON at low speed if the A/C is ON.......this includes any selector postion that activates the A/C....including defrost.
Above something like 40mph....they will go off.
The intent is to provide airflow over the condensor coils when you are stopped.....or not moving fast enough to have a decent air flow over them.
In fact, my '96 activates the A/C in heat also......so the ONLY positions that do not activate the A/C are vent and OFF.

My CCRM has been replaced 2 times.....once for radiator fan issue and once for A/C compressor issue.
As mentioned.....the CCRM is located in front of the battery, mounted on the back side of the driver's side radiator support.
Link to a view of the CCRM location.
http://rides.webshots.com/photo/1350...11220610XypyAI

The radiator fans also come on whenever the A/C compressor clutch is engaged.

The Low speed radiator fans turn on when the coolant temperature is 215 degrees F and shut off when the coolant temperature drops to 210 degrees F.

The High speed radiator fans turn on when the coolant temperature is 230 degrees F and turn off when the coolant temperature drops to 224 degrees F.

In the power distribution box, next to the battery in the engine compartment, Fuse "B" 60amp is for radiator fans high speed setting.......2 relays provide the power for high speed operation......due to the current.

Fuse "H" 40amp .....then through the radiator cooling fan dropping resistor provides power for the low speed operation.
Link to photo of dropping resistor location
http://rides.webshots.com/photo/2458...11220610ybouky


Fuse "W" 15amp is connected to the junction that is the power side of the radiator fan motor supply....after the power has passed through the relays and dropping resistor (only for low speed operation)........
There will be power at this point ONLY when the fans are activated.....
The other end of fuse "W" goes to pin 4 on the PCM.