The most likely is the vacuum line used to operate the swinging doors to redirect airflow is broken or not in place.
A bad heater core / it needs to be replaced
A blocked heater hose could cause a leak. A stopped up heater core could as well. Or the connector in the Windstar could be cracked.
Not unless your heater core leaks.
This "flap" is the temperature blend door which directs air over & through the heater core.The "Related Questions" below are intended to help explain some of the basics of Windstar heating/cooling functions and terminology.That should help in the investigation of the specific problem on the vehicle, and ultimately leading to a fix.Start with the "Where is the heater control valve located on a Ford Windstar" question and then move on to the "What could cause a Windstar to have no heat - or not be able to adjust the temperature"
thermostat stuck
Take it apart to determine the cause. Only then you will be able to fix it.
If the defroster is blowing hot air and it is still leaving moisture on the inside of the windshield, the heater core may be leaking coolant causing that condition. If the defroster is blowing cold air it could be the cooling system is low on coolant, or the thermostat is stuck open or the heater core is plugged up or the temp blend door has a malfunction.
No. The heater uses hot engine coolant that is run through what is effectively a small radiator. If the coolant is cold because the engine hasn't yet warmed up, then you are just circulating COLD water through the heater... no harm there. But SOMETIMES the defroster switch also activates the air conditioning system to dry out the air that is blown across the windshield. If the defroster is on when you start the engine it MAY cause the engine to idle a little fast and if the engine doesn't run well in the cold it may contribute to engine stalling. Beyond that, again, no harm there.
The AC is probably coming through the defroster because the air door is stuck. The door is behind the dash and is vacuum controlled. A vacuum leak or bad door will cause this problem.
probably heater core btw 8hrs have to remove whole dash
Most likely a film on the inside of a windshield is caused by an engine coolant leak within the heater core.
Most common things are Thermostat or a bad heater core but could also be something blocking the door down by the heater core. I changed my Thermostat and Heater control Valve to find out a pencil fell in the defroster and prevented the door from closing. Hope this helps.