WATER IN THE BLOWER CASE - BLOWER MOTOR AND/OR RESISTOR FAILURE
FORD: 2001-2004 Taurus
MERCURY: 2001-2004 Sable
ISSUE
Some vehicles built between 5/1/2001 and 12/15/2003 may exhibit water in the blower case or on the passenger side floor, an inoperative climate control blower motor, a motor that operates on high speed only, and/or a blower motor resistor failure.
SERVICE PROCEDURE
1. Access blower motor and resistor per the Workshop Manual Sections 412-02 and 412-04. Inspect for evidence of water/corrosion. If water/corrosion are found or parts have failed, replace per Workshop Manual (blower motor 1F1Z-19805-AA and resistor F6DZ-19A706-AA).
2. Visually inspect the Cowl Vent Screen located under the RH windshield wiper to verify if the screen is fully seated. Inspect the rubber seal against the windshield. If the cowl vent screen is not fully seated and appears warped, it must be replaced (4F1Z-54018A16-BAA).
3. Remove the cowl vent screen per the Workshop Manual Section 412-01 Pollen Filter Removal and inspect the cabin filter to confirm it is fully seated. Re-seat the filter as necessary. Inspect rain-hat base to make sure it is secure and sealed to the body. Reposition and reseal as necessary using Clear Silicone Rubber TA-32.
4. Remove the foam sealant expulsion at lower front outboard corner base of the rain-hat (Figure 1).
5. Locate the tape as shown (Figure 2). Remove the tape and apply Clear Silicone Rubber TA-32 to the small hole as shown (Figure 2). Download File PDF
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