Here's a general overview of the process. I strongly recommend consulting a repair manual specific to your year and model Windstar before attempting this. Repair manuals provide detailed instructions, diagrams, and torque specifications crucial for success.
Before You Begin:
* Gather Tools: You'll need a variety of tools, including screwdrivers (Phillips and flathead), sockets, wrenches, pliers, plastic trim removal tools, and possibly a torx bit set. A shop manual will list the specifics.
* Disconnect the Battery: This is crucial to prevent accidental shorts and airbag deployment.
* Consult a Repair Manual: This is paramount. A Haynes or Chilton manual, or a factory service manual, will guide you through the specific steps for your Windstar's year. The process can vary slightly between model years.
* Consider Alternatives: If you're not comfortable with this level of car repair, consider taking it to a mechanic. The labor cost might be less than the frustration of a botched repair.
General Steps (highly simplified and may not apply to all years):
1. Dashboard Disassembly: This is the most labor-intensive part. You'll need to remove various components of the dashboard, including the radio, climate control panel, glove box, and possibly parts of the center console. Be careful not to break any plastic clips. Take photos as you go to help with reassembly.
2. Locate the Blend Door Actuator: Once the dashboard is partially disassembled, you'll locate the heater blend door actuator. This is the motor that controls the blend door. It's usually connected to the blend door by a linkage or gear.
3. Assess the Damage: Determine if the blend door itself is broken or if the problem is with the actuator. A faulty actuator is usually easier to replace. A broken blend door often requires more extensive work, potentially needing to replace the entire HVAC housing.
4. Repair or Replacement:
* Actuator Replacement: This often involves disconnecting the electrical connector, removing the actuator's mounting screws, and installing the new actuator in reverse order.
* Blend Door Replacement: This is significantly more challenging. It might involve removing the entire HVAC housing, which is often difficult to access and requires careful removal of various components.
5. Reassembly: Carefully reassemble the dashboard components, ensuring all clips and screws are properly secured. Reconnect the battery.
6. Testing: Test the heater controls to verify that the blend door is functioning correctly.
Important Considerations:
* Year-Specific Differences: The exact procedure will differ based on the year of your Windstar. Consult a repair manual specific to your model.
* HVAC Housing Removal: Accessing the blend door often requires removing the HVAC housing. This is a significant undertaking.
* Plastic Clips: Be very careful when removing plastic clips and trim pieces. They are easily broken.
* Patience: This is a time-consuming job requiring patience and meticulous attention to detail.
Attempting this repair without proper knowledge and tools could lead to further damage. If you're unsure about any step, it's always best to seek professional help from a qualified mechanic.
