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There is no significant power at the three wire plug at the control knob, the three wires are directly wired to a potentiometer. In the five wire plug on the actuator there is a ground and twelve volts. To test knob, use a multimeter to check for changes in resistance from the middle to the outsides, and for a constant resistance on the outsides. Use a voltmeter to check for 12 volts at the actuator plug, hooking to the two wires that are diff colors than the three that go to the control knob. If you have 0 volts with key in run position, you prolly have blown fuse. The knob resistance can be checked regardless of key position. If turning the knob varies the resistance, and you have twelve volts in run, then your actuator is probably bad. iF turning the knob yields no change in resistance, than the knob is slipping and not turning the shaft it sits on.
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The Blend Door actuator on the Ford Windstar can be found by removing the glovebox. A broken blend door actuator is almost as common as a broken blend door itself. Typically, the fix requires disassembling the entire dash and replacing the whole plenum box, which can be a costly repair. Linked here is a video from www.heatertreater.net demonstrating how to access components of the plenum box for repair without disassembling the entire dash. heatertreater.net/Windstar%20Video.html This details the best DIY option on how to replace a broken blend door or actuator.
