how to fix 97-03 CCRM (relay box) so a/c works

Discussion in 'How-To's' started by jigsaw, Apr 23, 2007.


  1. jigsaw

    jigsaw New Member

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    what do u mean :?
  2. JackBauer

    JackBauer New Member

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    How bout 2nd generation?

    Where is the CCRM located on a 91? Can't find it. :roll:
  3. jigsaw

    jigsaw New Member

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    Re: How bout 2nd generation?

    thats cuz u dont have one :lol: only 97 and up (both SPI and Zx2) the 2nd gen ones (91-96) do have an a/c relay, but its a regular relay. i believe its located on the firewall. dont quote me on it, but i think they r next to ur windshield reservior or close to it, if im not mistaken there should be 2 of them. i think one of them is gray, but im not sure :?
  4. FB

    FB New Member

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    :D Thank you Jigsaw for your fantastic post. My sons excorts clutch was not engaging. After reading your post I took a look at the CCRM. Removed it and drilled out the rivets. On the bottom side of circuit board the solder that you have circled had an off color to it. I cleaned it up and added a little more solder to it. Putt it back together and installed it back in the car. To my surprise the clutch is now working and the cool air is great. Saved us $200+

    Thanks again to you and all others who post this good info.
    :D :D :D
  5. jigsaw

    jigsaw New Member

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    no problem, we are here to help each other out :)
  6. VolvoPunch

    VolvoPunch FEOA Member

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    Just wanted to let everyone know that i took the advice in this how-to and my A/C has worked great all summer. Nice and cooled.
  7. jigsaw

    jigsaw New Member

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    ^^ that's a nice car... if u ever want to mod it, this is the right place ;)
  8. Escortdad

    Escortdad Well-Known Member

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    My son bought his first car this summer, a very clean 2002 Escort SE. The air conditioning worked great one day and the next day nothing.

    My limited logic told me that unless he blew a refrigerant hose, it was likely an electrical problem. The fuse was good and the radiator fan kicked on when we turned on the AC, but the compressor clutch wouldn't kick in.

    This post saved us lots of grief and hours of troubleshooting. I'm sure we would have never thought of opening up the CCRM. For us, the solder touch up did the trick. And it was the exact same pin as circled in the photo.

    By the way, we used short 3/16 bolts and nuts to re-attach the circuit board to the mounting plate. It worked great. I think we had to use #8 bolts to re-attach the cover due to the tight space. Oh, and a 3/16 drill bit is just right to drill out the original rivets--you may have to waller it around a bit.

    Thanks for the awesome advice! :D
  9. homerdogg

    homerdogg New Member

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    replacing the a/c pressure switch

    This has been a very informative thread. Thanks for all of this shared knowledge.

    I have unpluged the harness from the pressure switch (on top of the accumulator) and put in a jumper on the wiring harness and my a/c now works. This tells me that the pressure switch is bad. My question is: does the refrigerant have to be evacuated from the system in order to change the pressure switch or can it just be removed with a wrench and replaced without a lot of hassel? Has anyone done this b4? What is the proceedure? Thanks in advance.
  10. madmatt2024

    madmatt2024 FEOA Member

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    It could also mean you are low on refrigerant. Just because it works doesn't mean it has the right charge. I think you do have to evacuate the system to replace the low pressure switch but I herd that you can replace the high pressure switch without evacuating.
  11. homerdogg

    homerdogg New Member

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    Thanks Matt, that thought occured to me about 1 minute after I posted my question. 8)

    I let the a/c run for a minute or two and sure enough, it wasn't blowing cold air. I added some R134a and everything is now fine. It turns out the pressure switch was just doing its job and I was gonna yank it out! :?

    Gotta remember the KISS (keep it simple stupid) method! :lol:

    I sure am glad I found this forum, because that damn ZX2 sure ain't easy to work on. It seems like one needs elf hands just to change the oil filter!
  12. ThrowinLead

    ThrowinLead New Member

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    Thanks for the info

    The A/C in my 98 wagon that I recently purchased wasn't working. I followed the instructions for re-soldering the compresser relay.

    I now have ICE COLD AIR! :p

    Thanks for the info - it saved me a ton of $$$ and was a simple fix.
  13. Lostboys

    Lostboys New Member

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    This is a older thread-i hope someone with info reads it soon.
    I went to do this repair today. I unbolted the CCRM module from the car no problem. Then when i went to unhook the wiring harness from the module it would not come loose at all. I tugged, pulled and pried on the thing and just could not get it loose for nothing. Exactly where and how does the harness come unhooked at? There is like a green cover type gizmo over the end, i tried pulling and prying on that with no luck. Then i tried prying closer to the module itself with no luck. Does the thing come unhooked at all? Im really lost here..........please help.
    I might post pictures of the thing tomorrow if i cant get it loose, maybe from that someone can tell me what part unplugs it. Im scared if i keep messing with it im going to damage some wiring.
  14. jigsaw

    jigsaw New Member

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    on the harness u will see it is held by a small bolt. flip the module with the harness side up and look on the center, it is a very small screw about 4.5mm or so ;)
  15. Lostboys

    Lostboys New Member

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    Thank you so much! How i missed that bolt is beyond me. Regardless, i got the unit off, did the solder job, put it back together and PRESTO we have air! For the first time in almost a year my air conditioning is working in my car and i couldnt be happier.
    I wonder how many little zx2s and escorts are running down the road needing this simple fix while the owners are sitting inside burning up with no idea of what to do. It seems like something like this would qualify for a manufacturers recall. But oh well. I guess all we can do is help spread the word to help others.
    Thanks again!
  16. masm60

    masm60 New Member

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    I think I have this problem. Where is the magic CCRM located on a 1998 ZX-2?
  17. Lostboys

    Lostboys New Member

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    I have a 2001-on mine its located right underneath the air filter housing. I imagine yours would be the same. Its a fairly large black box with large wiring harness sticking out of the side. You cant miss it. Its really not hard to get off or anything, fairly straight-forward.
  18. rick_r

    rick_r New Member

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    So if we take our wonderful Bush rebate money and get a new CCRM from online somewhere, it's really just taking the air filter housing off and plugging in a new box?

    I get the idea of greed, thanks, but why does the Ford dealer think they need $200 to do that?
  19. jigsaw

    jigsaw New Member

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    new CCRM comes with all the other relays. if ur fans, fuel pump, etc are working fine then it's worth a try to fix the old one. now when u spot an escort with the windows down ask if the a/c works if not then say "i'll fix it for $50" :p
  20. rick_r

    rick_r New Member

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    Oh, I meant $200 on top of the box to switch the thing out, for $400 total.

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