2003 passenger rear sliding door - will not shut

Our 2003 windstar has automatic rear doors. The passenger rear door will not shut all the way when closing onthe automatic setting - it will on manual. It gets most of the way and then backs off right at the end. We took it to the dealer and they wanted to:

replace the contacts
replace the optical sensor
align the door

Cost about $700. If it needs a module it would be another $500.

I have aligned the door myself but I was wondering about the other parts. Are they easy to get to and install?

I am not ready to dish that much money and instead may just keep using the manual option.

Hi there,
I'm having a similar problem. I took the van to the dealer but after 8 hours they still couldn't find the problem. Today I took off the panel and found the 'module'. It seems to be the brains of the whole rear door operation. My door will not respond to any of the switches; console, back seat button, or keyless entry. If opened manually the motor will engage and pull the door back it can also be closed with the rear button but it won't close all the way. I'm going to be checking the 'module' at my friends electrical shop tommorrow see if there's anything obviously wrong. I'll also swap out the module from the other side and see if it works on the malfunctioning side. I'll keep you updated. Anyone have any thoughts?

You're in the right area. Think of that module as being blind and dumb ... it only knows to "try" to move that door so many inches (unless it feels an extra mechanical load) and then it expects the switch at the rear of the door opening to be actuated.

So when you "adjust" the door for closing, it must also be with the drive cable taunt in the closed position.

Besides that, everything must be cleaned and lubricated ... this includes the various rollers and paths (upper and lower and cable path) ... make sure no debris is in the path of the door, especially at end-of-travel. Be sure the seven contact plunger slides are well lubricated so they won't resist the final inch or so of door closing. Use a spray lubricant on the rubber door surround seal.

There is a very large TSB that helps diagnose all the power sliding door problems. Shortly after buying my Windstar I had problems with the doors closing and latching the first latch but failing to catch the second latch, causing the door to click and move out a little. The info in the TSB helped me adjust both doors to get them in spec (front of door slightly inboard and rear slightly outboard) and I haven't had a problem since. Also it pointed out a couple pieces of plastic that they used to paint parts that were mistakenly left on the doors after assembly and increased closing effort.

Cleaning the door pad and plunger frequently has helped prevent any issues. Also, its easy to get items hidden in the track, found one of my son's socks stuck in there the other day.

Might be worth getting a subscription to www.alldata.com to get this TSB to help walk through the diagnosis.

A part of my problem is that the door will not open when any of the buttons are pushed. Alignment may also be an issue because it doesn't close properly. When the buttons are pushed I can hear relays clicing in the module, but no movement from the door motor.

lewisnc100
Do you happen to have the ID of that TSB? I'd like to get a copy.

TSB# 04-2-3 dated 02/09/04
Body - Power Sliding Door Operation/Diagnostics
Covers 1999-2003 Windstars, 2004 Freestars and 2004 Montereys

Thnx!