Option 1: Repair (More Challenging)
Actuators often fail due to worn gears, broken plastic components, or motor failure. Repairing is possible but requires disassembly and often finding replacement parts.
1. Removal: You'll need to remove the inner door panel to access the actuator. This involves removing screws, carefully popping off clips, and disconnecting various components like window switches and speaker wires. There are many online resources and YouTube videos showing this process specific to your Windstar year and model – searching "[Your Windstar Year] Door Panel Removal" is crucial.
2. Disassembly: Once you have the actuator in hand, carefully disassemble it. This often involves small screws and potentially clips. Take pictures at each step to remember the assembly order. This is where delicate work is required – broken plastic is a common problem during disassembly.
3. Diagnosis: Inspect the gears, motor, and linkages for damage. Common problems include:
* Stripped Gears: These are often plastic and wear out. Replacement gears are sometimes available online.
* Broken Plastic Components: Broken levers or linkage arms might need replacing or repairing with epoxy.
* Burnt-Out Motor: This requires a new motor, often the most expensive part to replace.
4. Repair/Replacement of Components: Replace the damaged parts. If you find replacement parts, carefully assemble the actuator, ensuring all gears mesh properly and linkages are correctly aligned.
5. Reassembly: Carefully reassemble the actuator and reinstall it into the door. Reconnect all the wiring and door panel components. Reinstall the door panel.
Option 2: Replacement (Easier)
This is usually the more reliable and less time-consuming method.
1. Removal (Same as above): Follow the same steps as above to remove the inner door panel and access the actuator.
2. Disconnect: Disconnect the electrical connector from the old actuator.
3. Removal of the Actuator: Remove the bolts or clips holding the actuator in place.
4. Installation: Install the new actuator, ensuring it's properly aligned and connected. Secure it with the bolts or clips.
5. Reconnect: Reconnect the electrical connector.
6. Reassembly (Same as above): Reassemble the door panel.
Important Considerations:
* Year and Model: Actuators vary by year and model. Ensure you get the correct replacement part.
* Tools: You will need various tools, including screwdrivers (Phillips and flathead), trim removal tools, and potentially a socket set.
* Online Resources: Search YouTube for "[Your Windstar Year] Door Lock Actuator Replacement" for visual guidance.
* Cost: Replacing the actuator is generally cheaper than a professional repair and often faster. Repairing might be cheaper if you can find replacement parts, but the time investment could make it less worthwhile.
If you're not comfortable working on car components, it's best to take your Windstar to a qualified mechanic. Attempting a repair without the proper knowledge and tools could lead to further damage.
