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My ignition key was free turning from stop to stop, but would niether start nor (after I got started by jumping the solinoid) turn off the ignition. I tried installing a new keyed ignition switch on the column and it did the same thing. By dropping the steering column, I could see that the...

Yes, you're right about that vacuum line at the bend near the rubber adapter. I found this earlier in my visual inspection and repaired it...didn't seem to change anything so I failed to mention it.

The flap is operated by vacuum. I can hear it closing when I place the control knob in the "vent" position. Also, the fan moves easily with (some) resistance. When the engine is off, it will not free spin, but can easily be turned. Is this O.K?

Ok, I'll spin the fan and try to determine the resistance. As far as the blend door, where would this be? I have a mutimeter, but no temp probe attachment.

..also I do not have the infrared gun...

Will do as soon as I can...not with vehicle at the moment (at work now)...later tonight. Can you tell me what it should and shouldn't feel like? What if it's tight? What if it's loose? ( We may be getting somewhere here...this could explain why the water temp guage always shows cool...right?)

No, not sure how this should be checked. Not an electric motor. What do I look for?

Mine is a 3.0.

Thank you for your reply. As I mentioned in my initial statement, I flushed 55 gallons of water through both hoses and through the heater core. I also backflushed through the block and radiator. The hoses and core are clear of obstructions. I'm curious about the control valve that was mentioned...

What heater control valve? The hoses go straight from the block/water pump right into the heater core. I called Autozone to see if they have a heater control valve for a 93 Aerostar and they don't list one. I suspected the control valve from the beginning, but there is no such animal on this...

The original thermostat was 195 as was the new one, both checked ok to application of heat (on a vise). The top heater hose was slightly hotter (very hot) than the bottom heater hose which was also hot. I flushed the enire engine in both directions with 55 gallons of hot water and replaced with...

The heater on my 93 Aerostar is not hot, only luke-warm. I have my second new thermostat. The water temp guage on the dash points at "N" on "NORMAL", but the coolant seems hot to the touch. How should I troubleshoot this?