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Ford Windstar Electrical Problems

334 messages,  Last post on Apr 26, 2013 at 6:05 PM

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What is this discussion about? Ford Windstar, Ford Windstar Cargo, Van

Messages Page 28 of 34

#264 of 334 Re: 2002 Windstar Electrical issues [notamechanic7] by oyokidude1

Oct 12, 2011 (2:39 pm)

Replying to: notamechanic7 (Oct 12, 2011 9:18 am)
Our alternator goes out basically 1-1/2 year intervals as well. I replaced the harness that goes to the (battery/starter/alternator/fuse box/ground) . I also got a brand new battery and Alternator (not re-manufactured) with a lifetime warranty.
at the same time a little while ago
 
Our 2001 SEL has 221,000 miles and counting..
 
Oh and a major fail on your part!!
 
FORD WINDSTARS TAKE ATF (AUTOMATIC TRANSMISSION FLUID) in the POWER STEERING.
 
SO IF YOU HAVE POWER STEERING FLUID running in it, PLAN on purchasing a new RACK AND PINON

#265 of 334 Re: 2002 Windstar Electrical issues [oyokidude1] by notamechanic7

Oct 13, 2011 (6:16 am)

Replying to: oyokidude1 (Oct 12, 2011 2:39 pm)
Luckily, when I went to get power steering fluid when I purchased the new power steering pump and wheel, the guy at Oreilly's told me that it takes Automatic Transmission Fluid. Thanks goodness there are a few people that work there that know what they are doing. I have never had to put power steering fluid (I mean ATF) in it, but I'm wondering what they do when they top off my fluids at the Qik-Lube when they change my oil? Do they know what they are doing? I think I will start doing most of the routine maintenance from now on. I've learned more than I've ever wanted to know about cars from this Windstar than any other vehicle that I've owned.
It was almost 1 1/2 years ago when we replaced the alternator last, so you are saying this is what I probably have to look forward to every 1 1/2 years? Great!

#266 of 334 Re: 2002 Windstar Electrical issues [notamechanic7] by oyokidude1

Oct 13, 2011 (6:48 am)

Replying to: notamechanic7 (Oct 13, 2011 6:16 am)
LOL, good thing you didnt put P/S in that. I had thought I one point that my P/S system was shot.
 
I drained out the P/S reservoir and put new Ford ATF (whatever was recommend in the manual.). Anyways it initially would growl and be hard to turn. Topping off as I was turning the wheel back and forth, it hasn't given me problems.
 
Anyways...
 
My rear windows stopped working. The passenger window broke AGAIN after it was fixed a few years ago. (we owned another 01' Windstar where the Passenger window did not function either)
 
The door lock actuators have basically crapped out, the front cheaper and easier to replace. The back actuators are a PITA to replace.
 
Overall we got 220k miles out of that van and it is still there....
 
Problems I have had with this van that i DIY (Living in Florida)
Sensors
IAC
MAF
DPFE
------
Upper Intake Bolts/Seals
Clogged EGR metering ports
Intermittent working windows.
Failing Door Lock Actuators
ABS/BRAKE light, failure of ABS module
Failure of Sway Bar Links (Clunk when turning at low speeds)
AC Blend Door Actuator
Door Ajar Warning (initially thought it was sensor, turned out to be a shorted wire in the door wiring harness)
 
Spark Plugs
Coil Pack
 
Multiple
Alternators
Batteries
 
New Battery Wire Harness
 
Rock in Rad/AC fan assembly
 
Pigtail tail light and turning signal connections
---
Other common problems lie with Failure of Transmission....

#267 of 334 Re: ford windstar electrical problems [gunner623] by frazzled5

Oct 14, 2011 (6:43 am)

Replying to: gunner623 (Oct 07, 2011 7:39 am)
Just purchased a 2002 Windstar last fall. Had all 3 recalls done on the vehicle. Had no issues before I had the recalls done. Now engine light, ABS and brake lights continually come on and have replaced batteries and alternator. Just curious if everyone's issues started after they had the recalls done on their vehicle.

#268 of 334 Re: ford windstar electrical problems [frazzled5] by oyokidude1

Oct 14, 2011 (7:58 am)

Replying to: frazzled5 (Oct 14, 2011 6:43 am)
I don't think ford techs are scheming, and causing problems. I doubt they think an owner would bring a $900-$4,500 van back to the dealership for repairs. I know for a fact an issue lies with the ABS MODULE ...
.
Remember you said you just purchased it..
LET THE PROBLEMS BEGIN =D
 
I live in the South so I don't have these axle snappings or rust problems...
 
visit
www.fordwindstarrecall.info
and read about the ABS module failure. Also report this Brake issue to http://www.nhtsa.gov/

#269 of 334 Re: ford windstar electrical problems [frazzled5] by aerostarfan

Oct 18, 2011 (3:48 pm)

Replying to: frazzled5 (Oct 14, 2011 6:43 am)
We just purchased our 2002 Windstar last fall too! and have replaced the alternator 3 times in 18,000 miles. All but one of the recall fixes had been done when we bought it, then the last was done. Other than eating alternators, it's a great ride but sadly, though it's been only 1K miles since alternator replacement #3, it appears the downward spiral leading to alternator death has begun again, since warning lights have started turning on and off randomly during driving.
 
Here's how the breakdown goes every time: for several weeks the warning lights get intermittently wonky (brake, seat belt and ABS warning lights come on and off randomly), next there will be incidents of gauges swinging wildly, A/C turning off, electric doors/windows failing, and then soon afterwards the engine (in the middle of driving just fine) starts to sputter, then dies, with the alternator dead and battery drained. After each alternator replacement, my regular mechanic then 2 different dealer mechanics said they checked every electrical wire circuit, connection, etc., and found nothing wrong - just sent us on our way with an "all fixed."
 
I know many would have dumped this van already, but we can't afford to replace it and need a way to transport elderly parents and pets who don't fit into our little Kia sedan. At this point, though, even with 11K miles left on the dealer's repair warranty, it's a safety issue to have elderly and pets on board if/when it breaks down again.
 
For now I'm driving with a battery/alternator tester plugged in at all times, hoping at least I'll KNOW when the alternator fries and can get to a safe place before the engine dies. The tester shines green (good) at first, then changes to green and yellow (low) after a few minutes of driving. It may be unrelated, but there is sometimes bad radio interference for awhile after the AC fan is turned on, and lately the AC takes about 10 minutes to blow cold air.
 
Does anyone have any suggestions for fixes we can try before we get rid of this van? I don't even feel right selling it, because I'm sure that's what the previous owners did, passing their misery on to us when we bought it. I don't want to do that to someone else.
 
Thanks in advance!

#270 of 334 Re: ford windstar electrical problems [aerostarfan] by notamechanic7

Oct 19, 2011 (5:48 am)

Replying to: aerostarfan (Oct 18, 2011 3:48 pm)
Well, I understand your misery. Our van is paid off, but we can't afford a new vehicle with 3 boys, 1 car payment and mortgage. This van is how my wife gets the kids to school and child care. Sometimes she takes their cousins to school.
As of now, the van is running great. Like you said, it rides and handles well. My wife loves it other than the electrical issues.
We just got a new alternator installed.
I only have a few suggestions:
1. Make sure the wire going from the battery to the fuse box goes under the air filter box. This was the beginning of my misery. This caused the short which drained my first battery and killed the alternator. They recharged the battery and put in a new alternator, but the battery did not last long.
2. Along with the new alternator, get a new battery.
3. Replace the Rear Electronic Module.
4. Replace the wiring harness if you notice any part of it that may seem burned. This is a short and will drain your battery and kill your alternator. Remember to put mechanics grease on all electric terminals.
5. Check the timing and any other routine maintenance items (again, I'm not a mechanic).
 
Every couple of days I am checking the battery because this seems to be where my problems stem from. If your Windstar is fully loaded like mine, then there are many things that can drain the battery. I hope this helps and you can do many of these things on your own. My wiring harness was from the Ford dealer and cost me $120, I put it on myself in about 30 minutes. I put a new starter on before that, but only to find that the battery was dead (mechanic told me it was the starter). This started the downward spiral of the alternator. The battery was dead because the wiring harness was bent at the fuse box instead of coming out straight and going under the air filter box.
Sorry for the rambling.

#271 of 334 02 Windstar SEL by yohan27

Nov 07, 2011 (7:08 pm)

I have a 2002 Windstar SEL, the driver's side power sliding door and the rear heater both stopped working shortly after I bought it in 2008. Sometimes if we hit a bump or go through a car wash they will both start working again all the sudden. In winter time the air bag light comes on. Sometimes a warning comes on to check charging system and the lights will dim so I turn the van off and restart it and it works again. Lately its draining overnight and at first I thought it was because the passenger power sliding door wasnt closing all the way but even when we make sure its closed it will still drain overnight. Is this all one problem or multiple problems? Dont really have the money to pay 400 in diagnostic work which is what the ford dealer told me it would cost just to find out whats wrong.

#272 of 334 Re: 02 Windstar SEL [yohan27] by notamechanic7

Nov 07, 2011 (9:45 pm)

Replying to: yohan27 (Nov 07, 2011 7:08 pm)
I don't know where you are from, but here, Auto Zone and Oreilly's both do free diagnostics. Any good mechanic would check your battery for dead cells and see if your alternator is working for a minimum charge or even free if you ask. If it is the alternator, try to get it at Oreilly's with the life-time warranty. Also, check the REM or rear electronic module. This seems to be a problem as well. Go over the wiring harness very closely looking for any signs of arching. This was the start of all my problems. 2 alternators, 2 batteries, diode (or whatever), and a starter later and I am hoping I finally got to the bottom of it. Good luck and keep us posted.

#273 of 334 Re: 02 Windstar SEL [notamechanic7] by yohan27

Nov 08, 2011 (3:22 am)

Replying to: notamechanic7 (Nov 07, 2011 9:45 pm)
I should have said, I had the battery and alternator both checked and they said both were functioning perfectly, dont know about REM ill have to check that out.

Messages Page 28 of 34

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