How do you remove the wiper arms and 2 piece cowl below the windshield on a Ford Windstar?

Answer 1

Removing the "cowling" is for anyone trying to access the coil pack, spark plugs, VSS, heater hoses, and anything else on the backside of the engine!

The extra effort and 15 minutes (less once you've done it a time or 2!) is so very much worth it!

The extra room you'll have will make the project go faster, but just as importantly: reduce the FRUSTRATION factor 10-fold.

Trust-us who recommend it. We've learned the hard-way.

• Start by removing the windshield wiper arms
  
  • Flip up the plastic cover over the base of the wiper arm
  • Remove the 15mm nut holding the wiper arm onto the wiper motor shaft.
  • The arm lifts straight up and off the shaft
    
    NOTE: The arm will lift off much easier when it's in the flipped-up-away-from-the-windshield position. That releases the spring tension against the shaft
    
    TIP - mark the wiper blade position on the windshield with a marker - good reference point for when you put them back on
    
  
  
• Remove the antenna (not applicable to 1999-2003 models)
  
  
• Remove the screws and bolts around the perimeter of the upper cowling
  
  1999-2003: 4 plastic screw-like fasteners across the length of the cowl, accessible with the hood up - remove the center screw and pull plastic base out of the hole
  
  
• There are 7 hidden clip-type fasteners across the top of the upper cowl - unsnap starting at one end
  
  
• Reach up underneath the upper cowl and pull washer fluid hose off the sprayer head / nozzle - don't bother with the hard plastic hose - go to the base of the nozzle
  
  
• The hard plastic washer fluid hose clips into the upper cowl about 1/2 way between the nozzles - it's not a tight fit, just keeps the hose from drooping. Pull the hose out of the clip
  
  
• The thick rubber strip across the front of the upper cowl has a snap in clip on each end - gently pry up - avoid ripping the rubber like I did on one
  
  
• Look at the screen underneath where the cabin filter sits - see those 2 fasteners - take those out too - a tack-remover-pry tool is perfect for those little ones
  
  NOTE: the upper cowl is now loose and can be removed
  
  TIP - wrangling the upper out is a pita with the hood fully open. Try and have someone around to hold the hood about 1/2 way up/down (your choice). It makes it easier!
  
  Disconnecting the lower cowl
  NOTE: there are 2 vent tubes that attach to the bottom of the lower cowl - just to the right of the cabin air filter section - it's best to disconnect them at the lower cowl, leaving them attached to the vehicle
  
  

• Remove the *black* screws / bolts around the lower cowling.
  If it's silver, then that is wiper motor mount / fastener! Do NOT take those off - you want the motor and linkage to remain firmly attached to the lower cowl.
  
  NOTES - There are 2 types of screws:
  
  • 2 on each end, total of 4
    
  • 6 longer ones, 5 of which attach those lower tubes/ducts to the upper cowl, and one that goes dead-center towards the top of the cowl.
    
  
  
• Disconnect the wire harness to the wiper motor.
  
  NOTE: don't bother with the hood-open plunger switch wire - it's all connected to the lower cowl
  
  
• Follow the washer fluid hose to the left and where it takes a 90 degree turn. This is a joint that is easy to disconnect just by pulling on it.
  
  
  The lower cowl is now loose and can be angled left-side forward and then some bit of twisting to clear the wiper motor and linkage.
  
  NOTE: The lower cowling will be heavy due to the wiper motor and wiper hardware.

Enjoy having all that OPEN SPACE to work in! It's almost as much as in the "good-old-days" of working on engines.