Mornin, DTR.
I've got a friend that has a Ford Windstar that is not running right... fairly new model maybe an 05-06. Yesterday, they pulled into a gas station and the van was running rough, no gauges, no electrical (windows, locks, dome lights, nothing...) After they shut it off, it would not crank. When we hooked cables to it, it fired right off, but as soon as we took them off, all the gauges died again. We got it to run enough to make it to their house, but I'm pretty sure that motor was running purely mechanical, there were no electrical systems working at all. It was firing on about 2 cylinders the whole way.

The battery looked fairly corroded... that's where I'm starting. After that, it's the alternator (don't think that's it), fuses, and lastly the ECM. I have not worked on these before, so if anyone has a link to a tech manual, or some advice, I could use it.

TIA!

mad

 

bad electrical connections can cause a loss of communication with the ECM. I would keep going like you are and clean/replace battery, cables (clean grounds on chassis side and positive on starter side). Chryslers are notorius for a bad battery causing cluster to freak out, abs lights, check engine lights etc and it was only a battery causing the whole problem

 

I know you are working on a ford but used chrysler as an example.

 

Dont lie Mark, you sold the madhat mobile for a grocery getter and got suckered....

But I agree with Chris, sounds like electrical gremlins. On bad passenger side battery on my mega cause all kinds of weird things to start happening.

 

Mark

The ford electrical system in particular, is VERY dependent on the battery as a load cell, as well as a buffer for the system. Since 1992 for sure, its been a constant source of amusement in colder weather. ( and I NEVER see cold weather)

You are going in exactly the right direction, keep up with cleaning the terminals, make sure they are tight, and go from there. Another spot I have seen go bad, more often than not, is the cables, right where they enter the terminal clamps. They get green in there, but you cannot see it. Check for that as well.

Another indicator of bad battery connections, is an overly hot alternator. Means it is charging to beat heck, but not having a whole lot of luck, due to resistance in the cables, or a loose connection.

Good luck

 

Thanks, fellas. Gonna go work on it now.

 

It was the alternator. Actually the easiest alternator I've ever changed out. Took me 10 to get it out, and 20 it get it and the battery back in. I'm actually impressed at the design. Glad I was not doing the AC compressor, tho!!!

 

Yeah, the alts on those windstars are really easy....... once you are sure that is the problem.

 

I saw it arcing, and then had it tested.

I hope that's all it was.