Windstar :: 2001 - Rear Auxiliary Unit Not Blowing Hot Or Cold Air
2001 Ford Windstar rear auxiliary unit will not blow hot or cold air. The front system works fine with very cold or very hot air as needed.The system has been in this state for the past four years.Last month I had a local shop evacuate the refrigerant and then I replaced the following A/C components (compressor, front orifice tube, rear expansion valve, receiver dryer, and condenser). The shop then recharged the system and the front blows ice cold air...amazing! Unfortunately the rear system just doesn't want to blow any air, hot or cold. To date I have completed the following checks:
Relays
- Front cabin relays #3 and #6 were swapped with no change to front system.
- Rear unit relays make a clicking sound when either front or rear control panels set blower motor speed.
-- I swapped out with front and rear cabin blower motor relays with no change to front blower motor.
Engine Compartment - Both 40A fuses were checked (117 & 120).They are supposed to be 40A fuses but my box had 50A in both places.It had been like this for years with both systems working fine up until the rear unit ceased working.(NOTE: maybe this is coincidence but when I changed these from 50A to 40A my son noticed that some of the rear tail lights stopped working. in fact all of them associated with fuse #7 located in the passenger cabin.)
Fuses - all related fuses were checked and are fine.As noted above the distribution box fuses were changed from 50A to 40A with no detrimental effect on the front system working.
Front Control Panel
- Heat and air work fine (blower and temp controls)
- Front control panel appears to change rear unit temperature setting but only one of blend door actuators adjust when changing temperature setting
-- The one closest to the blower motor does not function.The one that directs air to floor or ceiling functions properly.
-- Shouldn't they move together based on the temp setting?
- Front control panel blower motor settings only result in hearing a clicking noise for each setting.
- Setting front control panel to REAR CTRL allows rear control panel to function.
Rear Control Panel
- Temperature settings - same result as front control panel with blend door actuators.
- Blower motor settings - same result as front control panel.
Rear Auxiliary Unit
- Expansion valve makes a hissing sound on A/C or Defrost settings.
- Blower motor was removed and benched tested for operation.
-- Electrical connection looks fine and seats snug.
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