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Other Windstar Problems and Fixes

INDEX OF PROBLEMS

Problem Windstar ODBII Codes: P0171, P0174, P0301,P0302,P0303,P0304,P0305,P0306

Problem Windstar ODBII Codes: P0401, P0403, P0400, P0402,P0401

DOOR AJAR LIGHT STAYS ON - DOORS WILL NOT AUTO LOCK

Clunking Grinding/Moaning squeeky Struts

Heater fails to work, although the engine is hot.

Removing rear spark plugs

IAC - Idle Air Control Valve P-1507

Problem Windstar ODBII Codes: P0171, P0174, P0301,P0302,P0303,P0304,P0305,P0306

Code P0171 and P0174 171 and 174- System Lean in Banks 1 and 2. - This is problem with the Isolator rubber grommets in the intake manafold bolts. To fix it, order Fel Pro grommet set ES72204 (about $17). The pictures are wrong on the web sales pages. Remove the plenum cover. Remove the 8 isolator bolts one at a time, cut the old isolator off with wire cutters, slip the new one on and reinstall the bolt. Some pictures and procedures are here, but are quite overkill, remove the cover, replace the isolators 1 at a time and put the cover back on. It took me 1.5 hours. You need a 10mm deep well and shallow socket and an 8mm deep well socket. Below is a picture of a grommet I cut off, one is cracked the other is split in half. There was a Ford TSB 03-16-1 that explained the FIRST and primary source of the codes above are these isolator grommets.

I bought my grommets at Advance Auto Parts locally because shipping this item from on-line vendors made the price too much to pay.

There is also an outside chance the fuel pressure vacuum line is too loose and leaking vacuum. Below is my cheap solution.

Problem Windstar ODBII Codes: P0401, P0403, P0400, P0402,P0401

Code P0401 401 - EGR Flow - This is a common problem. There is a part that must be replaced every 60k. You must replace the DPFE (Differential Pressure Feedback Exhaust) switch. Costs about $40 delivered and can be replaced in the pipe mounted vehicles in about 3 minutes with a screwdriver to detach the electrical connector. Below is the a picture of the one my Windstar. I circled it. It pulls right off the tubes below it.

I bought mine at Rock auto dot com.

DOOR AJAR LIGHT STAYS ON - DOORS WILL NOT AUTO LOCK

This one is very simple. Spray WD-40 or like lubricant into the door latch on the doors. Be liberal and spray all around.

Also my hatch switches went bad. I just cut the wires and spliced them together.

CLUNKING over BUMPS or TURNING in Front End

Replace the Sway bar links in front $15 each (you need two) and Sway Bar Bushings $10. Total $40. Front end totally like new.

If your struts squeek/grind and moan, this is a problem with the strut design, Ford put a TSB out about using OEM plates/grommets on top of the strut to stop the noise of the bearing plate moving to the chassis of the van. I spray Wd-40 in the top mounting holes to stop the noise. Lasts about 2 months. Repeat as needed.

Oh those rear spark plugs.

If you have small arms, reach over the top right to find cylinder #3. Also reach around the left (above power steering) to get to cylinder #1. Get cylinder #2 from under the car. If you arms are a little bigger, try cylinder #3 and #2 from under. You can only get to the back passenger cylinder from the front you may have to remove the cowling.

Code P1507 Idle Air Control Valve - Threw P1401 too aux emmission control.

After trying to clean the Idle Air Controller I just decided to replce it. Less than $40 in parts and 15 minutes in labor. Documented here.

Blend door actuator - heater

There is an rather inexpensive part behind the dashboard in the radio area a little white box called the blend door actuator. It is filled with little plasic gears that strip out and must be replaced. This part is reponsible for moving the heater from hot to cold. Try this before a more expensive fix. There are many documented fixes on utube.