Engine/Transmission DRIVEABILITY Issues (06-14-10)

ENGINE/TRANSMISSION DRIVEABILITY ISSUES

TECHNICAL SERVICE BULLETIN

ISSUE

Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts / engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area.

ACTION

During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure.

SERVICE PROCEDURE

Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Fig 1 )

Fig 1: PCM Connector

Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Fig 2 ) If sealant is interfering with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead.

Fig 2: Body Sealant On Bulkhead

1. Remove the wiper pivot arm. (Fig 3 )
   1. Release pivot arm nut cover.
   2. Remove the pivot arm nut.
   3. Remove the pivot arm.
   Fig 3: Removing Wiper Pivot Arm

   
2. Remove the screws. (Fig 4 )
   Fig 4: Removing Wiper Pivot Arm

   
3. Release the clips.
4. Remove the windshield wiper hose.
5. Remove the upper cowl panel grille.
6. Disconnect the electrical connector. (Fig 5 )
   Fig 5: Disconnecting Electrical Connector

   
7. Remove the lower cowl panel assembly. (Fig 6 )
   1. Remove the ten (10) bolts.
   2. Remove the lower cowl panel assembly.
   Fig 6: Removing Lower Cowl Panel Assembly

   
8. Obtain two (2) PVC soft foam adhesive strips (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900).
9. Cut both of the PVC soft foam adhesive strips in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Fig 7 )
   Fig 7: Cutting PVC Soft Foam Adhesive Strip

   
10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM.
11. Place two (2) of the cut pieces of the PVC soft foam adhesive strips on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Fig 8 )
    Fig 8: Adhesive Strips On Body Surface Over Transaxle Area

    
12. Place the other two cut pieces of the PVC soft foam adhesive strips on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Fig 9 )
    Fig 9: Adhesive Strips On Body Surface Over PCM Area

    
13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Fig 10 )
    Fig 10: Rubber Plugs And Plastic Clip Locations

    
14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Fig 11 )
    Fig 11: Rubber Plugs On Bottom Of Cowl Sheet Metal

    
15. Install the lower cowl panel and 10 retaining bolts. (Fig 12 )
    Fig 12: Lower Cowl Panel And Retaining Bolts

    
16. Connect the electrical connector. (Fig 13 )
    Fig 13: Disconnecting Electrical Connector

    
17. Install the upper cowl panel grille.
18. Install the windshield wiper hose.
19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Fig 14 )
    Fig 14: Removing Upper Cowl Panel Screws

    
20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Fig 15 )
    Fig 15: Sealing Front Seam Between Upper And Lower Cowl

    
21. Install wiper pivot arms. (Fig 16 )
    NOTE: APPLY THREADLOCK TO THE PIVOT ARM NUT.
    Fig 16: Installing Wiper Pivot Arms

    
22. Check the wiper pivot arm adjustment.

PARTS INFORMATION

WARRANTY INFORMATION

WARRANTY STATUS:  Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.