Power lock problem
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Junior User
Joined: Jan 2012
Posts: 71
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From: Largo, FL
Power lock problem
Hi, i have a 1992 Aerostar. My power locks wont unlock when the red button is pressed. Locks fine though. The problem exists in both door controls. I replaced both controls and the problem remains. What else could it be that allows me to lock but not to unlock the doors? I will really appreciate any suggestion. Thanks in advance. 
Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
the problem is one of the wires from the locks to the interior of the van has broken, typical failure.
get a length of wire, long enough to go from the rear of the door lock connections to below the fuse box where you will find a connector with the same color wires as the door lock wires;
jumper each wire from the door lock to the connector wires of the same colors and test the lock each time, chances are you will find the bad wire.
after you find the bad wire, just get a metal clothes hanger, straighten it, tape the new wire to one end, and run the hanger through the door's rubber accordion until it comes out inside;
splice each end of the new wire to the bad wire at both ends.
get a length of wire, long enough to go from the rear of the door lock connections to below the fuse box where you will find a connector with the same color wires as the door lock wires;
jumper each wire from the door lock to the connector wires of the same colors and test the lock each time, chances are you will find the bad wire.
after you find the bad wire, just get a metal clothes hanger, straighten it, tape the new wire to one end, and run the hanger through the door's rubber accordion until it comes out inside;
splice each end of the new wire to the bad wire at both ends.
Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
I forgot to say that to run the new wire inside the door thru the rubber "accordion" and out to the interior of the van, you will have to pull the door panel and also the "kick panel" below the fuse box to do a neat job. You'll need a very long wire, like 4½-5 feet long.
also route the new wire from the door locks by spiraling the new wire over the existing wiring harness that goes from the door locks thru the accordion to the interior, taping the new wire to the harness every 3 inches, to avoid it getting caught in the glass window mechanism as it moves up and down.
for testing only, you do not need to do the above. Good luck.
Thread Starter
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Junior User
Joined: Jan 2012
Posts: 71
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From: Largo, FL
Had no luck! I opened both kick panels and check the wires with a multimeter from switch to switch, from actuators to switches, etc. The book says there is a lock relay and an unlock relay. Since both switches lock but wont unlock i think the problem is the unlock relay. The problem is i just cant find it. I looked everywhere. Any ideas where could it be?
Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
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Senior User
Joined: Dec 2006
Posts: 194
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From: Surrey BC Canada
The relay (dual coil) could be located in the right side door pillar, near the bottom. It has 6 inline connectors (A,B,C,D,E,F).
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Thread Starter
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Junior User
Joined: Jan 2012
Posts: 71
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From: Largo, FL
Yes i did, and everything seems fine. I will keep looking for those relays today.
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Junior User
Joined: Jan 2012
Posts: 71
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From: Largo, FL
Hi, thank you! Is that passenger side between the door and the sliding door, where the seat belt is?
Senior User
Joined: Dec 2006
Posts: 194
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From: Surrey BC Canada
Thread Starter
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Junior User
Joined: Jan 2012
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From: Largo, FL
I finally found the relay. I opened it and it was all rusty in the inside. I noticed the relay controls both the lock and the unlock. I cleaned it up really good with a little piece of sand paper and WD40 and got it working like new. Now the power lock works! Thank you both for all the help!! 
Senior User
Joined: Dec 2006
Posts: 194
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From: Surrey BC Canada
That's great to hear!
I am curious to know where your Door Lock Relay is located on your 92 Aerostar? On my 93 Aerostar, it is located near the bottom of the passenger side door pillar.
BUT... the official Ford 1993 Aerostar Service Manual INCORRECTLY states it behind the dash reinforcement panel, and then there other diagrams stating it is in the drivers side door pillar.
I am curious to know where your Door Lock Relay is located on your 92 Aerostar? On my 93 Aerostar, it is located near the bottom of the passenger side door pillar.
BUT... the official Ford 1993 Aerostar Service Manual INCORRECTLY states it behind the dash reinforcement panel, and then there other diagrams stating it is in the drivers side door pillar.
Thread Starter
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Junior User
Joined: Jan 2012
Posts: 71
Likes: 0
From: Largo, FL
That's great to hear!
I am curious to know where your Door Lock Relay is located on your 92 Aerostar? On my 93 Aerostar, it is located near the bottom of the passenger side door pillar.
BUT... the official Ford 1993 Aerostar Service Manual INCORRECTLY states it behind the dash reinforcement panel, and then there other diagrams stating it is in the drivers side door pillar.
I am curious to know where your Door Lock Relay is located on your 92 Aerostar? On my 93 Aerostar, it is located near the bottom of the passenger side door pillar.
BUT... the official Ford 1993 Aerostar Service Manual INCORRECTLY states it behind the dash reinforcement panel, and then there other diagrams stating it is in the drivers side door pillar.
Thank you again!
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