Tools You'll Need:
* New Brake Pressure Switch: Make sure you get the correct part for your year and model Windstar. Your local auto parts store can help with this.
* Wrench: The size will depend on the switch; it's typically a small metric wrench (likely 10mm or 11mm).
* Socket and Ratchet (optional): Might be easier than a wrench, depending on access.
* Shop rags or paper towels: To clean up any spilled brake fluid.
* Brake fluid: You might need to top off the master cylinder after disconnecting the switch. Have the correct type (DOT 3 or DOT 4) on hand.
* Protective Gloves: Brake fluid is corrosive.
* Container to catch brake fluid: A small jar or pan.
Procedure:
1. Safety First: Engage the parking brake firmly. This is crucial to prevent the vehicle from rolling.
2. Locate the Switch: The brake pressure switch is usually located on the master cylinder itself, often near the brake lines. It's a small cylindrical switch with a single wire connected to it. Consult your Windstar's repair manual or a diagram for the precise location if you're unsure.
3. Disconnect the Wire: Carefully disconnect the electrical connector from the switch. Sometimes this involves simply pulling it straight off, other times there might be a retaining clip.
4. Catch Spilled Fluid: Place your container under the switch to catch any spilled brake fluid.
5. Remove the Switch: Use your wrench or socket to carefully unscrew the brake pressure switch from the master cylinder. It's likely a threaded fitting. Go slow to avoid damaging the master cylinder threads.
6. Clean the Area: Use shop rags to clean any brake fluid from the master cylinder and surrounding area. Brake fluid is corrosive, so clean it promptly.
7. Install the New Switch: Carefully screw the new brake pressure switch into the master cylinder. Tighten it to the manufacturer's specifications (check your repair manual); don't overtighten!
8. Reconnect the Wire: Securely reconnect the electrical connector to the new switch.
9. Check for Leaks: Carefully check for any leaks around the new switch. If you see any leaks, tighten the switch slightly (if necessary), but be careful not to overtighten.
10. Top Off Brake Fluid: Check the brake fluid level in the master cylinder reservoir and top it off if necessary.
11. Test the Brakes: Start the engine and test the brake lights. They should illuminate when the brake pedal is pressed. Test the brakes thoroughly in a safe area before driving the vehicle.
Important Considerations:
* Repair Manual: A repair manual specific to your year and model Ford Windstar is highly recommended. It will provide detailed diagrams and torque specifications for your vehicle.
* Brake System Bleeding: In most cases, you won't need to bleed the brakes after replacing the pressure switch. However, if you have any concerns, it's best to consult a repair manual or a professional mechanic.
* Professional Help: If you're uncomfortable working on your brakes, it's always best to take your vehicle to a qualified mechanic. Brake system issues can be serious, and safety should always be your top priority.
This guide provides general instructions. Always consult your vehicle's repair manual for specific details and torque specifications. Improperly performing brake repairs can be dangerous. If you are uncertain about any step, seek professional assistance.
