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It sounds like you have a broken blend door. This is a very common issue with the Ford Windstar. Basically, the electronic actuator motor which moves the blend door is too powerful and over time it is almost guaranteed to break. Typically, in order to repair the blend door, a mechanic will disassemble the entire dash and replace the entire plenum box assembly, and it can be a very pricey fix in the $1000-$2000 range depending on your mechanic. There is an aftermarket product that can be found at www.heatertreater.net which is a DIY kit, where the blend door is replaced by removing the glove box and making a small incision in the plenum box. That way the blend door can be accessed and replaced without dash removal. It is a much cheaper alternative to having a mechanic replace the entire plenum assembly.
What else can I help you with?
1999-2003 Windstar with no heat - or cannot adjust temperature - just blows cold air?
you need a new heater door actuator motor about 50 dollars from ford.For a comprehensive review of Windstar "no heat" problems, see "Related Questions" below for more
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