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greetings and hopefully some good news for fellow victims of soggy PCMs and power loss and transmissions that won't go into reverse and $1000 fixes that don't work.
I too experienced all of the above, had the PCM removed and the Ford service fix for the problem installed only to get 350 miles and be stranded by the same problem.
Mechanics were at a loss to figure out the source of the water infiltration and the next step was to be a new wiring harness. turns out the new repairs were more than the "trade-in" value and I was reluctant to dump it on an unsuspecting private buyer.
So I figured if I was going to junk it I would just try to find the water source myself.
I followed the instructions for getting to the PCM by removing the wiper arms, special puller required, about $15 at most auto stores,don't try to pry, you'll wreck the pivot arm, removing the outer cowling, couple of screws and pops off the windshield side, removed the inner cowling, 10 screws. you'll have to remove the wiper fluid lines and connector to the wiper motor to get good working room and lift off the whole assy. just take your time and don't make things worse. or give this fix to your mechanic.
sounds difficult but actually only takes about 30 minutes if you have all the metric sockets.
now the PCM is locate under the dash on the passenger side. there is a 40 pin connector that has a mounting bolt that you can see from the engine compartment. carefully remove that bolt and the connector will back out so you can remove it. mine had water dripping out. Its not a good thing but don't panic yet.
there are 2 nuts that hold the boot cover over the PCM. you'll need a deep well socket or nut driver to remove them. 7/16 works but its 10mm metric.
pull off the cover and the PCM will pull out of its bracket. my replacement had water in it too. shook it out and gently heated witha blow dryer on low.
now carefully, reach inside the hole where the PCM bracket fits and feel if there is any moisture on the interior above where the PCM was installed. if it's wet I know your problem. The tubular cross member that supports the firewall is full of water.
Ford uses foam like Great Stuff to fill that tube, probably for sound deadening.
on my vehicle, both ends were foamed and the middle was not.
I removed the clips that hold down the outer cowling and there was an inch or so of water in the tube. the clips are not water tight and the gasket on the cowling make a nice dam to hold water on the clips and over many years the tube gradually fills until its gets to the cover plate over the PCM and you get stranded..
I pulled back the insulation in the middle of the cross member. drilled a 3/8 hole at the bottom using a cordless drill to keep from being electrocuted. and watched the Ford fountain spew out. I drilled holes on both sides as well and used them as blowout holes with my compressor. water blew out everywhere. I put a small heater on the areas and after 2 days and several blowouts the chamber is dry.
you'll need to dry out the PCM and connector. not too hot just drying it out low blowdryer. check the gasket around the pins on the PCM and make sure it is around all the pins. this is the seal to prevent moisture from getting into the connector.
to test you can just slip the PCM in the bracket, install the boot and carefully install the connector and start the car. My trouble lights all cleared and the car ran fine.
if all is good reassemble in reverse order.
I purchased new clips from Ford and siliconed all them in. I thought about filling the member with foam but opted to just leave the middle hole for drainage.
My thought is that the crossmember was supposed to be entirely filled with foam.
There would never had been the internal leak if it was filled.
I think some were and some were not would explain why we had the problem and others think the Free Star was the best car ever.
Best to a
http://nhthqnwws111.odi.nhtsa.dot.gov/acms/docservlet/Artemis/Public/Pursuits/20- 10/PE/INOT-PE10033-41489.pdf
Best wishes.
I have a feeling that the PCM (when it WAS wet...the connector that is) destroyed the ignition coil (or caused my misfires and THEN caused the crack in the ignition coil).
Question: How many misfires are required to kill the sparkplug? I JUST replaced them last week...with GOOD ones too!
Thanks!
Wow! That will probably only make sense to another Freestar owner! Can't wait to get under my hood and see what I can see! Good Luck!
to report that your Ford Transmission is slipping out of gear at highway speeds. They are doing on a investigation on this right now
to report that your Ford Transmission is slipping out of gear at highway speeds. They are doing on a investigation on this right now
to report that your Ford Transmission is slipping out of gear at highway speeds. They are doing on a investigation on this right now
I would really apprecite any info on this issue.
Marcie
I would encourage you to phone Senator Carper's office. They have been working on this issue for me. Please let them know.
If you look at the complaint summaries on the NHTSA website, you can view all of the documents pertaining to the investigation. The lead investigator sent a letter to Ford on Nov. 16 requesting a bunch of info such as the number of warranty claims they've had for this issue. Ford has until Jan to respond, so I'm hoping a recall is made at that time.
Thanks.
This issue needs some attention from the news media, and I believe that this is the only way to let them know we mean business. We need to be heard, we need them to resolve this situation, and we need them to fix this wrong.
If any of you are willing to take part, please post on the list, and we can continue this dialog. Regards.
The recall impacts nearly 575,000 Ford Windstar models for model years 1998 through 2003 and produced from September 1997 through February 2003. Ford said the recall is for Windstars currently registered or originally sold in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.
Ford told the government that corrosion over time can weaken the axle and, when combined with stress, can lead to the axle breaking. A Ford spokesman said the company had received a small number of reports of fractures that "affected vehicle handling."
"Corrosion and stress can lead to cracks, which if undetected can propagate and result in a complete fracture of the axle. Consequence: a fractured axle can affect vehicle handling and increase the risk of a crash," said the recall. The states were chosen because they are ones where corrosion is quite common, said the Ford spokesman.
Ford also warned, "A completely fractured rear axle may lead to loss of vehicle control. There may be little or no warning to the operator before a cracked rear axle completely fractures."
So, we got it towed to the Ford dealership where we bought it from a year ago. The van has 74,000 miles and when we bought it last August it had 54,000 miles, that gave me a whole 20,000 miles with the van. Ford looked at the van, diagnoses: bad transmission; for a new transmission it would cost $3,500 to fix if there are not additional complications while they're replacing it. They gave two other options; a transmission with 60,000 miles on it or a transmission with 120,000 miles. Though why would I trust a transmission that has close to the same or more miles than what mine has.
At this point we felt it may be a good idea to work a deal with the dealer. There best offer was to give us $2,500 trade-in on the van that we paid $9,500 for a year ago, and no deal on a new car, this was today on new year's eve when I thought they had year end sales. In other words they did not attempt to help us with anything so were having the van towed to Aamco to have the transmission rebuilt hoping it will be less than the quote ford gave me. And to get our van out of there they tried to charge us $200 for the diagnoses, until my wife threw the credit card on the table and complained about the price. The cashier asked if we would like to speak to the manager, she came back and our bill changed to $94.
So, I would like to be part of the law suit. I filled out a form at the website of Shepherd, Finkelman, Miller & Shah, LLP Is this the place to go?
Our 2005 Freestar has been towed three times. The first time in it was a TCM issue--yes water!
The dealership: " We found water in the connector--the module is OK."
The next time (about a month later), my wife pulled in to pick up our two daughters at day care and after a restart no movement. Engine ran fine but absolutely no transmission engagement. Torque converter failure--replaced under warranty--barely!
Third time: symptoms like all the rest--sputtering, failure to shift smooth, stall, wild tachometer....
Dealership: Failed TCM--water again. "We siliconed the housing to keep water out." Me: "Why is the water getting in?"
Today, after about 6 months of normal operation, the van stalled on highway with no warning. All the same symptoms are back--stalling, engine and trans lights on, sluggish shifting, wild tachometer.......
It is now out of warranty and I'm not sure what to expect. I'm faced with either limping in to the dealership AGAIN or towing it--probably will take both efforts! I'm VERY interested in a class action suit or anything I can do to get Ford to recall. Please advise.
My 3 kids and I were driving home to Ky from Ga when our 2006 Freestar gave out in Spartanburg SC. As with everyone else no forwarning!
Luckily I was able to get off the interstate and coast into a gas station parking lot! My kids were terrified (they're 12, 10 and 8)! We had to wait 4 hours for my brother and dad to get to us; by then I finally got a local wrecker/service company to get the van out of the parking lot!
Just spoke to mechanic: $1800 for rebuilt trans or $2100 for used!!!
Like everyone else I owe more than what it's worth! I have filed with Nhtsa
any other suggestions?
NEVER again will I buy a Found On Road Dead. I'm a die hard GM customer from now on!! :confuse:
Does anyone have a link to the complaint/suit that they can post in a more recent posting?
It would be greatly appreciated.
Thanks
Tamara :lemon:
Does anyone know of a lawsuit pending for the transmission on a 2004 Freestar?
Anyone know of a class claim to join?