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I have a 1994 Aerostar 3.0 ltr, 5-speed manual tranny that was ordered new by my father. I have owned it since 2002 and it just turned 380,000 kilometers.
Presently air will only blow out the defroster. No matter what position the switch is in, vent, floor, a/c, etc. air only comes from the widshield defroster. It's been doing this for a few weeks now except a few days ago for a few seconds when some air came out the vents with the switch in the vent position. Then it stopped and would only come out the defroster again. Also when I turn on the rear fan, nothing is coming out the rear vents.
Now I never use Max A/C because as soon as I step on the gas pedal, air stops coming out the vents and would take forever for the air to flow again. Normal A/C worked better. If I stepped hard on the gas pedal, the A/C would stop for a split second and then flow out the vents again.
I'm assuming all this works off of vacuum, but I have no idea where to start. The Haynes manual that was given to me with the van looks like it's for an older van and is useless.
Ok, lets take this one step at at time. The vents defaulting to vent suggests a broken or disconnected vacuum line. The door that directs the air is powered by a vacuum motor, and the lines that run it get brittle over time. They frequently break off. They should be the lines running near the main harness on the passenger side. The proper way to replace these lines is to get the appropriate sizes replacement hose and some plastic elbow and tee fittings to make your bends and stuff. It really isn't that difficult to do. If possible, zip-tie your lines away from heat sources.
Pop the hood and take a look at the upper left side of the engine compartment. You will see some real thin plastic lines. Inspect these especially the fittings where they "T". If you are lucky you will find the problem there. If not, trace the lines until you find the leak/break. Worst case is that it is in the plenum under the glove compartment....you'd have to take that apart.
I finally had time to take a look at it last night at my parents' place. There were 2 broken likes in the engine compartment. One black and one white. Unfortunately I didn't have any vacuum hose that small in my toolbox. Once back in the city, I stopped by a Canadian Tire store and got some. Everything's working perfectly now. Thanks everyone.