I'm new to this site and hope I pick yalls brains. I have and am getting help on another ford forum. But with this forum I see that yall have e150 van specific so here goes. On my 97 with the blower at full speed it feels like our escort on low. With three of the vents closed I will feel it out of the vent next to the driver door. I sit with the seat at its furthest position if this helps. It's a light breeze at the steering wheel. On low you can have your hand at the vent and barely feel it. Is this normal to anyone who has this van. It's been this way for 5-6 yrs I've just started worrying about it due to health. This is what I've done to it new blower motor,new resister,opened up the ac evap core box and cleaned it,checked that the vac motors work on top of the dash they do. It dose switch from vent,floor and defrost. On max ac the lower door opens. Today I have taken out the radio and checked for leaks none found. The only thing I found is when on max ac there is some air coming out of the floor vents too. Any help from here would be greatly appreciated. Thank you and sorry for long post.

 

Did voltage test today. Got three different test. Done at the plug by the motor.
blk red both
1 low 9.49 14.3 4.4
2 6.5 14.1 7.4
3 3.6 14 10.2
4 high .85 13.9 13
If this helps with anything. Please help me figure if this thing is working normal or this is all I'll get out of it. Thank you.

 

Since I have never checked the voltage readings as you did I can't comment on them.
This is what I would try, remove the blower motor and connect wires directly to it and see if it runs at full speed. Don't worry when it does you will know it.
If it does not , then as long as your meter will measure amps , check how much current it is pulling. Just because it's new it could still be defective.
If it runs good at hi speed wired direct then I would suspect a problem with a poor connection with either the blower switch or the function switch (max-norm-vent etc)
The blower switches were troublesome because of the high current requirement of the blower motor and the wire connections at the switch became overheated to the point that the switch and the plug and wiring to the switch had to be replaced.. When you get the dash opened up and look at the back of the switch if you see melted connections you found your problem.

 

Ok I am actually getting ready to pull the climate controls out. One thing I forgot to put in is that on defrost it blows harder(more air output)than ventor floor. Thanks sir

 

I can't offer any explanation for that, but have you been able to verify that the intake for the blower is not blocked or partially restricted? Could an incorrect squirrel cage wheel been installed on the blower motor by someone else in the past?

 

The intake for the blower is clear. The blower to the ac evap core is clear. The fresh intake is clear. The cage I don't know if it is wrong or not. From the fit it looks right. I put it back on the way I took it off. The blower was factory if that helps.

 

I don't recall having any problems with the blower output from any that were not previously opened.
Untill you can actually see into the passages with a flashlite and mirror I guess you will have to keep looking for the problem.

 

Thank you sir.

 

You are most welcome sir!
I just wish I could have offered some better ideas.
Keep plugging , that how a lot of tough problems get solved.

 

Found out today from a guy that has the same van. Same model from the same lot and same conversion company just one month older. I asked him how his system was and we got to talking. All to find out he is a ford tech too whoot. Well these models and new models are know to be this way. So I have been chasing ghost all this time. Now I feel like a idiot now. Could anyone tell me where to get the rear system diagram for the relays and temp door. Have no luck in finding these thing. Thanks for the help and time.