2002 FORD WINDSTAR maintenance

Determining if the system is operational
The supplemental restraint system uses a warning indicator in the
instrument cluster or a back-up tone to indicate the condition of the
system. Refer to theWarning lightsection in theInstrument cluster
chapter. Routine maintenance of the air bag is not required.
A difficulty with the system is indicated by one or more of the following:
²The readiness light (same light
for front and side air bag system)
will either flash or stay lit.
²The readiness light will not
illuminate immediately after ignition is turned on.
²A series of five beeps will be heard. The tone pattern will repeat
periodically until the problem and/or light are repaired.
If any of these things happen, even intermittently, have the supplemental
restraint system serviced at your dealership or by a qualified technician
immediately. Unless serviced, the system may not function properly in
the event of a collision.
How does the air bag supplemental restraint system work?
The air bag SRS is designed to
activate when the vehicle sustains
longitudinal deceleration sufficient
to cause the sensors to close an
electrical circuit that initiates air
bag inflation.
The fact that the air bags did not
inflate in a collision does not mean
that something is wrong with the
system. Rather, it means the forces
were not of the type sufficient to
cause activation. Front air bags are designed to inflate in frontal and
near-frontal collisions, not rollover, side-impact, or rear-impacts unless
the collision causes sufficient longitudinal deceleration.
Seating and Safety Restraints
158

If you ever smell exhaust fumes of any kind inside your vehicle,
have your dealer inspect and fix your vehicle immediately. Do
not drive if you smell exhaust fumes. These fumes are harmful and
could kill you.
Have the exhaust and body ventilation systems checked whenever:
²the vehicle is raised for service
²the sound of the exhaust system changes
²the vehicle has been damaged in a collision
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. In addition, certain fluids contained in vehicles and
certain products of component wear contain or emit chemicals known
to the State of California to cause cancer and birth defects or other
reproductive harm.
Important ventilating information
If the engine is idling while the vehicle is stopped in an open area for
long periods of time, open the windows at least 2.5 cm (one inch).
Adjust the heating or air conditioning (if equipped) to bring in fresh air.
Improve vehicle ventilation by keeping all air inlet vents clear of snow,
leaves and other debris.
BRAKES
Your service brakes are self-adjusting. Refer to the scheduled
maintenance guide for scheduled maintenance.
Occasional brake noise is normal and often does not indicate a performance
concern with the vehicle's brake system. In normal operation, automotive
brake systems may emit occasional or intermittent squeal or groan noises
when the brakes are applied. Such noises are usually heard during the first
few brake applications in the morning; however, they may be heard at any
time while braking and can be aggravated by environmental conditions such
as cold, heat, moisture, road dust, salt or mud. If a ªmetal-to-metal,º
ªcontinuous grindingº or ªcontinuous squealº sound is present while braking,
the brake linings may be worn-out and should be inspected by a qualified
service technician.
Driving
179

TRAILER TOWING
Trailer towing with your vehicle requires the optional trailer tow
electrical package and may require the use of an additional medium duty
trailer tow option package.
Trailer towing puts additional loads on your vehicle's engine,
transmission, axle, brakes, tires, and suspension. For your safety and to
maximize vehicle performance, be sure to use the proper equipment
while towing.
Follow these guidelines to ensure safe towing procedure:
²Stay within your vehicle's load limits. If exceeded, cargo should be
removed from the trailer and/or the vehicle until all weights are within
specified limits.
²Thoroughly prepare your vehicle for towing. Refer toPreparing to
towin this chapter.
²Use extra caution when driving while trailer towing. Refer toDriving
while you towin this chapter.
²Service your vehicle more frequently if you tow a trailer. Refer to
Special Operating Conditions in the scheduled maintenance guide.
²Do not tow a trailer until your vehicle has been driven at least 800 km
(500 miles).
²Refer to the instructions included with towing accessories for the
proper installation and adjustment specifications.
If your vehicle is equipped with the optional heavy duty trailer tow
wiring, it is pre-wired for trailer towing. An electrical connector is
provided under the instrument panel for installing a customer-supplied
electric brake controller. Another electrical connector is provided at the
hitch. This connector provides power to the trailer for taillamps, stop
and turn lamps, back up lamps, battery charge, electric brakes (when a
customer provided controller is installed) and ground. The kit included
with your vehicle provides you with adaptors to attach the brake
controller and convert the hitch connector for Class I trailer usage.
Driving
195

Exceeding the GCWR rating may cause internal transmission
damage and void your warranty coverage.
Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to your scheduled maintenance guide for
more information.
Trailer towing tips
²Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
²Allow more distance for stopping with a trailer attached.
²If you are driving down a long or steep hill, shift to a lower gear. Do
not apply the brakes continuously, as they may overheat and become
less effective.
²The trailer tongue weight should be 10% of the loaded trailer weight.
²After you have traveled 80 km (50 miles), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
²When stopped in traffic for long periods of time in hot weather, place
the gearshift in P (Park) and increase idle speed. This aids engine
cooling and air conditioner efficiency.
²Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer's wheels.
RECREATIONAL TOWING
Follow these guidelines for your specific powertrain combination to tow
your vehicle with all four wheels on the ground (such as behind a
recreational vehicle).
These guidelines are designed to ensure that your transmission is not
damaged due to insufficient lubrication.
Driving
198

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
26 10A Airbag Module, Passenger airbag
deactivated indicator, Passenger
Seat Weight Pressure sensor ECU
27 Ð Not Used
28 10A Cluster
29 Ð Not Used
Relay 1 Ð Switched System Power Relay #4
Relay 2 Ð Accessory Delay Relay
Relay 3 Ð Front Blower Motor Relay
Relay 4 Ð Switched System Power Relay #3
Relay 5 Ð Rear Defrost Relay
Relay 6 Ð Auxiliary Blower Motor Relay
Power distribution box
The power distribution box is located in the engine compartment. The
power distribution box contains high-current fuses that protect your
vehicle's main electrical systems from overloads.
Always disconnect the battery before servicing high current
fuses.
Always replace the cover to the power distribution box before
reconnecting the battery or refilling fluid reservoirs
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and specificationschapter.
Roadside Emergencies
208

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
121 20A** Ignition Switch, Rear Defrost
Relay (coil)
122 40A** RH Power Seat Motors, RH Power
Lumbar Motor
201 Ð Not Used
202 Ð Front Wiper ON/OFF Relay
203 Ð Rear Wiper Relay
204 Ð A/C Clutch Relay
205 Ð Horn Relay
206 Ð Not Used
207 Ð Fuel Pump Relay
208 Ð Not Used
209 Ð Front Wiper Hi/Low Relay
301 Ð Starter Interrupt Relay
302 Ð High Speed Engine Cooling Fan
Relay
303 Ð Low Speed Engine Cooling Fan
Relay
304 Ð Powertrain Control Module Relay
401 Ð Not Used
501 Ð Powertrain Control Module Diode
502 Ð Not Used
503 Ð Not Used
* Mini Fuses ** Maxi Fuses
CHANGING THE TIRES
If you get a flat tire while driving, do not apply the brake heavily.
Instead, gradually decrease your speed. Hold the steering wheel firmly
and slowly move to a safe place on the side of the road. If your Low tire
warning light is on, refer toLow tire warningin theMaintenance and
specificationschapter.
Roadside Emergencies
212

In some states (in the U.S.) you must directly notify Ford in writing
before pursuing remedies under your state's warranty laws. Ford is also
allowed a final repair attempt in some states.
In the United States, a warranty dispute must be submitted to the
Dispute Settlement Board before taking action under the Magnuson-Moss
Warranty Act, or to the extent allowed by state law, before pursuing
replacement or repurchase remedies provided by certain state laws. This
dispute handling procedure is not required prior to enforcing state
created rights or other rights which are independent of the
Magnuson-Moss Warranty Act or state replacement or repurchase laws.
FORD EXTENDED SERVICE PLAN
You can get more protection for your new car or light truck by
purchasing Ford Extended Service Plan (Ford ESP) coverage. Ford ESP
is an optional service contract which is backed by Ford Motor Company
or Ford Motor Service Company (in the U.S.) and Ford of Canada (in
Canada). It provides the following:
²Benefits during the warranty period depending on the plan you
purchase (such as: reimbursement for rentals; coverage for certain
maintenance and wear items).
²Protection against covered repair costs after your Bumper-to-Bumper
Warranty expires.
You may purchase Ford ESP from any participating Ford and Lincoln
Mercury and Ford of Canada dealer. There are several plans available in
various time, distance and deductible combinations which can be tailored
to fit your own driving needs. Ford ESP also offers reimbursement
benefits for towing and rental coverage.
When you buy Ford ESP, you receive Peace-of-Mind protection
throughout the United States and Canada, provided by a network of
more than 5,000 participating Ford or Lincoln Mercury and Ford of
Canada dealers.
If you did not take advantage of the Ford Extended Service Plan at the
time of purchasing your vehicle, you may still be eligible. Please contact
your dealer for further information. Since this information is subject to
change, please ask your dealer for complete details about Ford Extended
Service Plan coverage options, or visit the Ford ESP website at
www.ford-esp.com.
Customer Assistance
227

THE DISPUTE SETTLEMENT BOARD (U.S. ONLY)
The Dispute Settlement Board is:
²an independent, third-party arbitration program for warranty disputes
²available free to owners and lessees of qualifying Ford Motor Company
vehicles
The Dispute Settlement Board may not be available in all states. Ford
Motor Company reserves the right to change eligibility limitations, modify
procedures and/or to discontinue this service without notice and without
incurring obligations per applicable state law.
What kinds of cases does the Board review?
Unresolved warranty repair concerns or vehicle performance concerns as
on Ford and Lincoln Mercury cars and Ford and Lincoln Mercury light
trucks which are within the terms of any applicable written new vehicle
warranty are eligible for review, except those involving:
²a non-Ford product
²a non-Ford dealership
²sales disputes between customer and dealer except those associated
with warranty repairs or concerns with the vehicle's performance as
designed
²a request for reimbursement of consequential expenses unless a
service or product concern is being reviewed
²items not covered by the New Vehicle Limited Warranty (including
maintenance and wear items)
²alleged personal injury/property damage claims
²cases currently in litigation
²vehicles not used primarily for family, personal or household purposes
(except in states where the Dispute Settlement Board is required to
review commercial vehicles)
²vehicles with non-U.S. warranties
Concerns are ineligible for review if the New Vehicle Limited Warranty
has expired at receipt of your application and, in certain states eligibility
is dependent upon the customer's possession of the vehicle.
Eligibility may differ according to state law. For example, see the unique
brochures for California, West Virginia, Georgia and Wisconsin
purchasers/lessees.
Customer Assistance
228