I have a couple of questions to ask. 1) When I turn on my headlight the instrument panel will intermittently not light up. Is this a known problem for this concern and any one know the remedy for this problem? And with the HVAC, when I turn the HVAC to max a/c (even though is won't be until spring or summer) I have problems with the a/c wanting to turn off at times almost like automatic climate control, but it isn't that. Any one know the issue to this and maybe have a picture of the problems since the repair manual aren't worth a crap trying to help me out. Please help. Brian

 

sounds like the headlights switch rheostat is going down. Have you tried moving the rheostat (Dimmer) a number of times from zero to 10 to sort of clean any oxidation?

As always, substituting a suspicious part is the fastest if not the best troubleshooting.

when you say "a/c wanting to turn OFF", does the fan/blower turn OFF or does the compressor turn OFF ? or both?

 

As far as headlights, when the cluster light go out I have to turn the headlight switch a numerous amount to get the lights to go back on. As far as the a/c, It only happens at a/c max. The blower motor shuts off, but the a/c compressor cycles normally, but this only happens in the a/c max mode. Please help. Brian

 

I have not had those symptoms in any of my Aerostar, but if you have to turn the switch a good number of times, then it does sound like a bad dimmer, which is built into the switch. I would remove the switch and spray contact cleaner to see if it improves it, or try to fit another switch to see if it eliminates the symptom.

to remove the switch ****, you need a "L" shaped pick, turning the **** until you see a "V" or "U" shaped cutout, then you insert the pick in there and pry upwards while pulling the ****.

the only thing that comes to mind in the blower-fan problem is the overpressure switch mounted in the Accumulator bottle, but I am not sure if that switch controls the fan too. Maybe others can help better.

 

Spend $20 on a new headlight switch, the one you have is going out and could be a fire hazard. Ford did have issues with these in the older models.

As for the max A/C, you are not quite clear on what is going on, is the blower motor completely shutting off when you select max a/c or is the a/c not working on max?

 

he says the blower motor shuts off when he selects MAX A/C.

 

Have you checked the blower motor speed control resistor wires? A blower wire harness plugs into the assembly, which is usually installed in the air box. The connector may be loose, and disconnecting at high air flows. Just a guess.

 

good idea.

If he has rear-auxiliary air system, he can transfer the rear Resistor to the front and see if the problem stops. It could be the resistor going bad since it controls the fan speeds.