I have the same issue, sounds like a blend door problem. Could be up to 800.00 to fix it....My 1999 Expy would blow out cool air if I played with the controls, now I only have hot air. The rear air works fine when changing the temps
you may also try the heater valve which is under the hood , the heater hoses hook to it .. i have a 99 expy with a 5.4 and my front and rear heat were dramatically fdiff. in heat neither were hot .. i changed the heater valve and waalaa .. now 16 degrees 15 mins snow melts off my windshield .. u ...
no heat front defrost dsah.
you will have coolant in your passenger front floorboard and when you turn your heater on your windshield will fog up
Climate control the temperature
You can replace the balls in the heater control panel on an XS ARA Picasso by removing the front cover of the heater control panel. The panel lights will then be visible.
The dash has to be removed. Once the dash is out, the top of the heater case comes off to gain access to the core.
Remove the center console remove the floor vent remove the heater core cover the heater core is right under the climate control unit remove the two screws that hold the heater core in place, open the hood and remove the heater hose from the heater core lines, now go inside and pull out the old heater core you don't have to remove the whole dash just the front of it
There are two heater core hose that goes to the firewall the inlet and outlet. through that hose, you will also have the rear heater core hose attached to a T joint in both the inlet and outlet hose. You splice the hose of the front heater core inlet and connect that to the rear heater core inlet hose. Same goes to the Outlet hose with the T joint using a conncetor which you can buy at your auto parts store, 3/4 inch size. Basically you are bypassing the front heater core that is connected to the firewall. You wont have any defroster and heater for the front, but the rear vents and control will have heat.
the fan control is on the left side of the heater control assembly, center of the dash. the resistor block which is probably what your asking about is above the front seat passengers feet behind the hush panel.
may be your heater control valve
In addition to the front core in the dash, if the van has the optional rear climate controls there will be a second one back there.See "Related Questions" below for lots more about Windstar heater cores and climate controls
I had the same problem and ended up replacing the blower resistor and the blower motor. Although it could be one or the other .. mine was both.
Not all models had a heater control valve. If it has one it's either right in front of the firewall by where the heater hoses go in, or else under the dash near the heater core.