For those of you who fixed blend door or pulled plenum...

jjue · October 1, 2002

How did you get the plenum out? I believe that I loosened all nuts and bolts, but the plenum seems stuck. It doesn't even seem as if the heater core is causing it to stick either. If this helps the blower motor and evaporator core housing does pull out. I also got the one nut that is behind the intake manifold. Am I forgetting to disconnect something here?

This has been a pain the the butt! :frustrate I've been working on this since 10:30 this morning taking breaks here and there for food and to lookup stuff.

yob_yeknom · October 1, 2002

Removal

1. Disconnect the battery ground cable.

2. Recover the refrigerant; refer to «Section 412-00».

3. Disconnect the A/C cycling switch.

4. Disconnect the electrical connectors.

1 Disconnect the A/C blower motor (19805) electrical connector.

2 Disconnect the A/C blower motor resistor (19A706) electrical connector.

5. Disconnect the heater core (18476).

1 Disconnect the heater water hoses (18472).

2 Disconnect the heater water control valve vacuum hose.

6. Position the speed control servo (9C735) aside.

1 Remove the (A) bolt and disconnect the (B) servo electrical connector.

2 Position the speed control servo aside.

7. Remove the two nuts and the two screws from the windshield washer reservoir/coolant recovery tank. Set the tank aside.

8. Use Spring Lock Coupling Disconnect Tool (3/4 in) to disconnect the A/C manifold and tube from the suction accumulator/drier.

9. Use Spring Lock Coupling Disconnect Tool (1/2 in) to disconnect the condenser to evaporator tube.

10. Disconnect the (B) A/C system vacuum harness and the (A) A/C evaporator housing mounting nut inside the vehicle.

11. Remove the A/C evaporator housing (19850).

1 Remove the three underhood and one underdash nuts.

2 Lift the A/C evaporator housing out of the vehicle.

From my service manual CD. Hope it helps.

tbomb · October 1, 2002

what exactly is the issue you guys are trying to fix here?

jjue · October 1, 2002

Nevermind, I found the 3 nuts that I forgot the remove. Now I'm at the point where I'm trying to get the stupid plenum to line backup up to the firewall.

jjue · October 1, 2002

Some of the explorers have the infamous blend door problem where I get either all hot air or cold air on A/C Max. Basically, the actuator breaks the hole that it fits in, causing the door to be closed in either heat or AC, leaving no mix of air whatsoever.

Yes, I have the CD too. Unfortunately, I didn't find the part about the plenum on the inside from the CD. I found it in the Haynes manual. I guess that I'll have to keep both afterall.

Robb · October 1, 2002

Jeffrey,
I take it you have a blend door problem and replacing it yourself(?). If you could, when you complete it, could you please post as much info as possible on the fix. Pics Preferably! If not, a complete detail of tips and tricks and total time required would be extremely helpful to those with this problem.

TIA

Robb

jjue · October 1, 2002

Don't worry, I've got plenty of pics for all to see. I guess that I'm gonna have to join the Elite club so that I can get all of these pics up here.

Robert · October 1, 2002

I'm sure someone would be more than willing to pay for your Elite membership if you go over and fix their broken blend door.

jjue · October 1, 2002

Considering that I'm putting up for tonight to finish installing the dash, center console, and steering column, I think that it will take more than Elite membership to go fix someone else's Explorer.

This thing has been terrible. No wonder the dealer wanted $900. Let's see so far I think that I have accumulated 11 hours including meals, running errands (in mom's van), talking on the phone, and researching this and other stuff on the internet. So, maybe 8-9 hours so far. I should be finished and driving with the correct air temperature by mid-afternoon, hopefully before the hurricane blows stuff from the coast all the way to Memphis covering everything in between, especially Jackson.

yob_yeknom · October 3, 2002

Originally posted by jjue
Some of the explorers have the infamous blend door problem where I get either all hot air or cold air on A/C Max. Basically, the actuator breaks the hole that it fits in, causing the door to be closed in either heat or AC, leaving no mix of air whatsoever.

Do you still get a mix of air on other settings?

I get heat when on vent and whatever and the selector is turned to warm air. And cold air when on A/C and the selector is set to cold. But it's hard to get just warm air and not hot air when on heat, and cool air and not really cold air when on A/C. When on max A/C, it's freezing cold regardless of where the selector is set to. Is that normal?

jjue · October 3, 2002

My air is mixing fine after the repair. A/C Max is normal. I'm not sure about the rest, but it still could be either blend door or lack of R-134a.

For those of you who fixed blend door or pulled plenum...

jjue

Elite Explorer<br>sXc Member

yob_yeknom

tbomb

Explorer Addict

jjue

Elite Explorer<br>sXc Member

jjue

Elite Explorer<br>sXc Member

Robb

Explorer Addict

jjue

Elite Explorer<br>sXc Member

Robert

Explorer Addict

jjue

Elite Explorer<br>sXc Member

yob_yeknom

jjue

Elite Explorer<br>sXc Member

Explorer Features

Explorer Features

Similar threads

Featured Content