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Discussion Starter #1 (Edited)
Hi everyone,

I own a 2002 Mercury Sable GS (equipped with the optional GS Plus Package) with the Vulcan engine. Car has 194K miles and I've owned it since August 2015. I'm having some issues that I need guidance on, since I've replaced various items but it still needs some work.

1: Lukewarm/cool heat. Car's equipped with manual (not auto) HVAC controls. I've had the heater core flushed multiple times, heater core replaced, coolant flush, and thermostat all replaced within the past 3-4 years yet I'm still having this problem.

2: Very intermittent stalling/stuttering from idle. Check engine would come solid on, but never blink. Spark plugs and plug wires were replaced within the past couple years. Code came up as a cylinder 6 misfire.

3: Intermittent electrical issue. Sometimes, when I open the glove box or mess with the dome lights, the power windows won't roll up or down and the dome lights/glove box light/exterior puddle lights will turn off. The little lights for the window switch buttons will also turn off too.

If you guys can help me out, I greatly appreciate it! I am STUMPED on those 3 issues despite multiple trips with my local mechanic.
 

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Can anyone help me please??? I really do need some assistance on my issues that my local mechanic seems stumped on despite me having replaced several parts already. I joined this website to obtain help.
 

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Can anyone help me please??? I really do need some assistance on my issues that my local mechanic seems stumped on despite me having replaced several parts already. I joined this website to obtain help.
This website is a relic of the past, most people have moved on to facebook, so it's not that people are intentionally ignoring you. The regulars aren't on as much as they used to be. With that said, the search function will help you find other people with similar issues, since we've seen it all pretty much.

With that said your heat issue is very likely a bad blend door actuator that's stuck the blend door in between heat and A/C if you've replaced all that other stuff. If you get more heat while at higher RPM then it's a failing water pump, if it's always the same lukewarm then it's the blend door.

For the intermittent stalling I'd do a voltage drop test on the block, and clean up the main battery ground point as well as the PCM ground strap point and see if that helps. I'd also check your alternator output at idle.

Finally, the random electrical issue is hard to say, but all of those items are on the same circuit. I'd check the fuse for starters, maybe it's not inserted all the way or something simple like that.
 

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This website is a relic of the past, most people have moved on to facebook, so it's not that people are intentionally ignoring you.
I've searched in the past for this facebook site I've seen mentioned, but couldn't find it. Could someone post a link please? TIA!
 

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Discussion Starter #5
I've searched in the past for this facebook site I've seen mentioned, but couldn't find it. Could someone post a link please? TIA!
Try this link.

Also, I just got word from my local mechanic: the front timing cover, timing chain, and timing cover gasket need to be replaced. He's also going to flush the heater core. Hope this works out...despite setting me back about a grand.
 

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Try this link.

Also, I just got word from my local mechanic: the front timing cover, timing chain, and timing cover gasket need to be replaced. He's also going to flush the heater core. Hope this works out...despite setting me back about a grand.
Is the front cover leaking coolant? The chain is probably still alright, maybe a little bit of slack at that mileage but I doubt it makes noise. But I guess he might as well while he's in there. As far as flushing the heater core, I'd have him put a new water pump on instead. Is it original? Generally speaking you might need 1 heater core through the life of these cars and that's only if you didn't do regular coolant changes and let the block start rusting internally.
 

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Discussion Starter #10
Is the front cover leaking coolant? The chain is probably still alright, maybe a little bit of slack at that mileage but I doubt it makes noise. But I guess he might as well while he's in there. As far as flushing the heater core, I'd have him put a new water pump on instead. Is it original? Generally speaking you might need 1 heater core through the life of these cars and that's only if you didn't do regular coolant changes and let the block start rusting internally.
My mechanic has now replaced the timing chain, front timing cover & gasket. Heater core flush was done too. Water pump was replaced 3 years ago, heater core replaced 1-3 years ago but don't recall when exactly. He suggested a new thermostat so I ordered the part and he'll replace it next week. The one I ordered was a Motorcraft 197* one.
 

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My mechanic has now replaced the timing chain, front timing cover & gasket. Heater core flush was done too. Water pump was replaced 3 years ago, heater core replaced 1-3 years ago but don't recall when exactly. He suggested a new thermostat so I ordered the part and he'll replace it next week. The one I ordered was a Motorcraft 197* one.
Most likely the secondary blend door is warped. Here is a link the the factory service bulletin: Taurus: the secondary blend door as per TSB 02-23-6
This was the fix for mine, I pulled the part from a 2005 Taurus at the J-yard.
 

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