steering FORD WINDSTAR 2003 2.G User Guide

Canadian customers who require roadside assistance, call
1–800–665–2006.
If you need to arrange roadside assistance for yourself, Ford Motor
Company will reimburse a reasonable amount. To obtain reimbursement
information, U.S. Ford or Mercury vehicles customers call
1-800-241-3673; Lincoln vehicle customers call 1–800–521–4140.
Canadian customers who need to obtain reimbursement information, call
1–800–665–2006.
ROADSIDE COVERAGE BEYOND BASIC WARRANTY
In the United States, you may purchase additional roadside assistance
coverage beyond this period through the Ford Auto Club by contacting
your Ford or Lincoln Mercury dealer.
Similarly in Canada, for uninterrupted Roadside Assistance coverage, you
may purchase extended coverage prior to your Basic Warranty’s Roadside
Assistance expiring. For more information and enrollment, contact
1–877–294–2582 or visit our website at www.ford.ca.
HAZARD FLASHER
The hazard flasher is located on the
steering column, just behind the
steering wheel. The hazard flashers
will operate when the ignition is in
any position.
Push in the flasher control and all
front and rear direction signals will
flash. Press the flasher control again
to turn them off. Use it when your
vehicle is disabled and is creating a
safety hazard for other motorists.
Note:With extended use, the flasher may run down your battery.
FUEL PUMP SHUT-OFF SWITCH
FUEL
RESET
This device stops the electric fuel pump from sending fuel to the engine
when your vehicle has had a substantial jolt.
After an accident, if the engine cranks but does not start, this switch
may have been activated.
Roadside Emergencies
151

Standard fuse amperage rating and color
COLOR
Fuse
ratingMini
fusesStandard
fusesMaxi
fusesCartridge
maxi
fusesFuse link
cartridge
2A Grey Grey———
3A Violet Violet———
4A Pink Pink———
5A Tan Tan———
7.5A Brown Brown———
10A Red Red———
15A Blue Blue———
20A Yellow Yellow Yellow Blue Blue
25A Natural Natural———
30A Green Green Green Pink Pink
40A——Orange Green Green
50A——Red Red Red
60A——Blue—Yellow
70A——Ta n—Brown
80A——Natural—Black
Passenger compartment fuse panel
The fuse panel is located below and to the left of the steering wheel by
the brake pedal. Remove the panel cover to access the fuses. To remove
the fuse panel cover, pull up on the latch on the top left side of the
cover.
To remove a fuse use the fuse puller tool provided on the fuse panel
cover.
Your vehicle is equipped with a Pull Fuse feature that when used, can
extend the duration of your battery life while your vehicle is parked for
long periods of time. This time will be increased from 31 days to 45–55
days (based on option content). You should use this feature when your
vehicle will be parked for long periods of times to ensure the vehicle
starts upon your return.
The pull fuse is located under the instrument panel and is visible from
the exterior of the fuse panel cover.
Roadside Emergencies
153

The fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse Panel
Description
1 10A Stepwell lamps, Puddle lamps, 2nd row
reading lamps, 3rd row reading lamps, Cargo
lamp, Dome lamp, Map lamp, Visor/Vanity
lamps, Remote Keyless Entry (RKE) keypad,
Turn signal mirrors
2 25A I/P Courtesy Lamps, Video Cassette Player
(VCP)
3 15A Power mirror motors, Adjustable pedal motor,
Memory module (if equipped)
4—Not used
5 20A Console power point
6 15A Radio, Compact Disc (CD) changer, RKE
module, Power Sliding Door (PSD) module,
Rear seat radio controller (if equipped), Rear
seat entertainment module (if equipped)
7 15A Left rear turn lamp, Backup lamps, Right stop
lamp, Right rear park lamp, License Lamps
8 20A Rear electronic module (RHF/RH sliding/LH
sliding/Liftgate door lock motors, Aux. air
blend door motor, Aux. air mode door motor)
9 10A Cluster, Powertrain Control Module (PCM)
relay (coil)
10 15A Heated backlite relay (coil), Speed control
module, Anti-lock Brake System (ABS)
module or IVD Module, Heated seat switch (if
equipped), Heated seat module (if equipped),
Cluster, Front temp blend door actuator,
Brake shift interlock solenoid, PCM, PSD
module, Reverse Sensing System (RSS),
Front A/C control head, Steering wheel angle
sensor (if equipped)
Roadside Emergencies
155

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box Description
117 40A** Auxiliary blower relay coil, Auxiliary blower
motor
118 50A** Left-hand PSD module
119 30A** Fuse junction box bus #1
120 40A** Front blower relay coil, Front blower motor
121 20A** Ignition switch, Rear defrost relay coil
122 40A** Right-hand power seat motors, Right-hand
power lumbar motor
201—Not used
202—Front wiper ON/OFF relay
203—Rear wiper relay
204—A/C clutch relay
205—Horn relay
206—Not used
207—Fuel pump relay
208—Not used
209—Front wiper HI/LO relay
301—Starter interrupt relay
302—High-speed engine cooling fan relay
303—Low-speed engine cooling fan relay
304—PCM Relay
401—Not used
501—PCM diode
502—Not used
503—Not used
* Mini Fuses ** Maxi Fuses
CHANGING A FLAT TIRE
If you get a flat tire while driving:
•do not brake heavily.
•gradually decrease the vehicle’s speed.
•hold the steering wheel firmly.
•slowly move to a safe place on the side of the road.
Roadside Emergencies
160

INSTRUMENT PANEL AND CLUSTER LENS
Clean the instrument panel with a damp cloth, then dry with a dry cloth.
•Avoid cleaners or polish that increase the gloss of the upper portion of
the instrument panel. The dull finish in this area helps protect the
driver from undesirable windshield reflection.
Do not use chemical solvents or strong detergents when cleaning
the steering wheel or instrument panel to avoid contamination of
the air bag system.
•Be certain to wash or wipe your hands clean if you have been in
contact with certain products such as insect repellent and suntan
lotion in order to avoid possible damage to the painted surfaces.
INTERIOR TRIM
•Clean the interior trim areas with a damp cloth, then dry by wiping
with a dry, soft, clean cloth.
•Do not use household or glass cleaners as these may damage the
finish.
INTERIOR
For fabric, carpets, cloth seats, safety belts and seats equipped with side
air bags:
•Remove dust and loose dirt with a vacuum cleaner.
•Remove light stains and soil with Ford Extra Strength Upholstery
Cleaner (E8AZ-19523–AA).
•If grease or tar is present on the material, spot-clean the area first
with Motorcraft Spot and Stain Remover (ZC-14).
•Never saturate the seat covers with cleaning solution.
•Do not use household cleaning products or glass cleaners, which can
stain and discolor the fabric and affect the flame retardant abilities of
the seat materials.
Do not use cleaning solvents, bleach or dye on the vehicle’s
safety belts, as these actions may weaken the belt webbing.
Cleaning
185

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
3.8L OHV V6 engine
1. Brake fluid reservoir
2. Air filter assembly
3. Power distribution box
4. Battery
5. Automatic transmission fluid dipstick
6. Engine oil dipstick
7. Engine oil filler cap
8. Windshield washer fluid reservoir
9. Engine coolant reservoir
10. Power steering fluid reservoir
345678
91012
Maintenance and Specifications
190

CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid.
Refer to the scheduled maintenance
guide for the service interval
schedules. If adding fluid is
necessary, use only MERCONAT F.
1. Start the engine and let it run until it reaches normal operating
temperature (the engine coolant temperature gauge indicator will be
near the center of the normal area between H and C).
2. While the engine idles, turn the steering wheel left and right several
times.
3. Turn the engine off.
4. Check the fluid level in the reservoir. It should be between the MIN
and MAX lines. Do not add fluid if the level is within this range.
5. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the correct operating range. Be sure to put the
cap back on the reservoir.
BRAKE FLUID RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels between the“MIN”and
“MAX”lines are within the normal
operating range, there is no need to
add fluid. If the fluid levels are
outside of the normal operating range, the performance of your brake
system could be compromised, seek service from your dealer
immediately.
MAX
MIN
Maintenance and Specifications
211

•Inflating a low tire will not clear the Low Tire Warning indicator light.
Only reseting the system will clear the light.
•The system will not detect a pressure loss without driving the vehicle
for at least 0.8 km (0.5 mile) at speeds greater than 40 km/h
(25 mph).
To reset the system if equipped
with Tire Reset switch:
turn the ignition to the ON position,
press and hold the“TIRE RESET”
switch (located on the instrument
panel behind the left side of the
steering wheel) for three seconds.
The low tire warning indicator light
will flash three times as the low tire warning system begins to initialize.
To reset the system if not
equipped with Tire Reset switch:
turn the ignition to the ON position,
depress and Trip/odometer button
(located in the instrument cluster)
until“TIRE RESET”or“CHECK
TIRE AND RESET”is displayed in the odometer display window. Once
“TIRE RESET”or“CHECK TIRE AND RESET”is displayed, press and
hold the button for three seconds. The low tire warning indicator light
will flash three times as the low tire warning system begins to initialize.
The system normally requires 15 to 20 minutes of driving in each of
three speed ranges to learn how the tires behave after the system has
been reset. However, the system will become functional in each speed
range as soon as learning completes in each individual speed range.
Speed ranges:
•Low 40–68 km/h (25–42 mph)
•Medium 68–100 km/h (42–62 mph)
•High–above 100 km/h (62 mph)
This system may not function properly under the following conditions:
•Uneven tread wear.
•Driving on loose or low traction surfaces such as gravel, snow or slush.
•Using tire chains
•Initial tire pressures out of specified range.
Tire
Reset
Maintenance and Specifications
216

Fluid Ford Part
NameApplication Capacity
Engine coolant
2Motorcraft
Premium Engine
Coolant
(green-colored)
or
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)Without rear
heater14.0L (14.8
quarts)
With rear heater 15.0L (15.9
quarts)
Power steering
fluidMotorcraft
MERCONAT FAll Fill to line on
reservoir
Fuel tank N/A All 98.4L (26.0
gallons)
Automatic
transaxle fluidMotorcraft
MERCONV
AT FAll 13.0L (13.7
quarts)
Windshield
washer fluidUltra-Clear
Windshield
Washer
ConcentrateAll Fill to line on
reservoir
1Use only brake fluids certified to meet Ford specifications. Refer to
Lubricant Specificationsin this chapter. DOT 3 fluid is recommended.
However, if DOT 3 is not available, DOT 4 fluid can be used.
2Add the coolant type originally equipped in your vehicle.
Maintenance and Specifications
221

Item Ford part
nameFord part
numberFord
specification
Lock cylinders Penetrating and
Lock LubricantMotorcraft XL-1 none
Power steering
fluidMotorcraft
MERCONAT FXT-2-QDX MERCON
Automatic
transaxle
(4F50N)Motorcraft
MERCONV
AT F
2
XT-5-QM MERCONV
Disc brake
caliper railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-3 ESE-M1C171-A
Constant
velocity jointsMotorcraft CV
Joint Grease
(High Temp.)XG-5 WSS-MIC25B-A1
Windshield
washer fluidMotorcraft
Ultra-clear
Windshield
Washer
ConcentrateZC-32–A WSB-M8B16–A2
1Use only brake fluids certified to meet Ford specifications. DOT 3 fluid
is recommended. However, if DOT 3 is not available, DOT 4 fluid can be
used.
2Ensure the correct automatic transmission fluid is used MERCONand
MERCONV are not interchangeable. DO NOT MIX MERCONand
MERCONV. Refer to the scheduled maintenance guide to determine the
correct service interval.
Maintenance and Specifications
223