So I recently had my vent mode actuator (still don't know the official name of this actuator) stop functioning. The actuator was stuck on the floor vents. I read this post, which helped a lot, and found the location of the actuator I needed. The 3D drawing on the first page of the post, and the ghetto drawing over top the 3D drawing actually helped significantly. The person that listed what each blue highlighted component was, was also a great help. The actuator I needed was definitely number 1 on the list. I went through a very basic diagnosis process to figure out that was the broken component, and I think I got a little lucky with that part. However, I'm not going to bore you with diagnosis, I'm going to tell you the easiest way to remove and replace that component.
The tools I used for the job:
Trim removal kit from harbor freight:
Trim And Molding Tool Set 5 Pc
Dewalt electric drill. Obviously doesn't have to be Dewalt. Any drill would work.
Handheld screwdriver with interchangeable bit head.
Dewalt Right angle flex shaft:
https://www.lowes.com/pd/DEWALT-Right-Angle-Flex-Shaft/1000282635
Dewalt Pivoting Magnetic Bit Holder:
https://www.lowes.com/pd/DEWALT-3-1-2-in-Magnetic-Screwdriving-Bit-Holder/3421552
Dewalt Magnetic 5/16 Nut Driver Bit:
https://www.lowes.com/pd/DEWALT-FlexTorq-5-16-in-x-2-in-Nutsetter-Impact-Driver-Bit/3422438
9/32 Nut Driver Bit
Craftsman Flex Claw Pickup Tool:
https://www.lowes.com/pd/CRAFTSMAN-Flexclaw-Pickup-Tool/1000594933
Flexible LED Tip Flashlight (similar to this one):
https://www.amazon.com/Streamlight-...flexible+led+flashlight&qid=1569721656&sr=8-7
12" Long flat head screwdriver. You could get away with any long, skinny prying device.
For the job, I only needed to remove 2 pieces of trim and the instrument cluster. I DID NOT have to remove the brake pedal, gas pedal, or dash to remove and replace this part. I'm not saying my way is the right way to do this, but I managed to get the piece out and a new piece in. As a caveat, the SAE nut driver bits I used had some play in them. I'm sure there is a metric equivalent that I should have used, but these worked for me.
1. Start by removing the plastic trim piece by the brake pedal. You'll need the 9/32 Nut Driver Bit. It should only have 2 bolts near the OBD port. Remove those bolts and finagle the piece out.
2. Lower the steering wheel to the lowest possible setting. Use the trim tools to remove the trim around the instrument cluster. It just clips in, with the two primary clips being on the top of the cluster. It's also attached to the steering wheel with a leather-esque flap. This piece of trim was also plugged into an electrical plug on the lower right side for some reason. Disconnect this, and remove the trim piece.
3. Remove the instrument cluster. It has 4 bolts. 9/32 Nut Driver Bit again. You can use any combination of the flex shaft and pivoting bit to get these bolts out. The instrument cluster pulls straight out. It has a single electrical connection. I couldn't get the plug out, and I actually left the instrument cluster attached for the entire process. It wasn't hard to work around.
4. You'll be able to see the actuator now. It is behind a metal bar (possibly the frame?), on the right side. I used the Flexible LED flashlight to fish through and find how this was attached. You'll be able to get 2 of the 3 bolts holding the actuator in from this part. One is nearest you on the upper-most portion of the actuator. The other is on the farthest side of the actuator towards the engine approximately upper middle of the actuator. To remove these bolts, I originally used a 3/8 in. drive ratchet, with a 5/16 socket, a Universal joint, and five 3/8 extenders at approximately 15" long. I DO NOT RECOMMEND THAT APPROACH!!! It took a lot of patience to get those 2 bolts out. I was also switching my approach from entering from the top, to trying to reach the bolts starting from the brake pedal. Big mistake. You can EASILY remove both of these bolts with the Right Angle Flex Shaft, using the Pivot adapter, and the 5/16 nut driver bit from this upper (and more comfortable) position. I'd HIGHLY recommend getting the magnetic version of the tools. The bolts SHOULDN'T fall out when using the magnetic tools. Once you shove this contraption into the cavity above the metal bar and below the vent ducting, you'll quickly realize your hand doesn't fit in there, and the pivot adapter keeps falling when you try to place it on the bolt. No problem. Use the flex claw to grab the pivot adapter, and precisely guide the nut driver bit to the bolts. It worked like a charm for me. I forgot to attach the drill originally, and I just grabbed a screwdriver with the interchangeable bit head, and used that. Once you remove both bolts, then the "fun" part begins.
5. Bolt 3 you will have to get from the brake pedal floor board area. At least, that's what I had to do. The 2013 Explorer Limited I have has the adjustable brake/accelerator pedals. I don't know if that helped me with the job, but I figured I'd use them and set them as close to the engine as possible. I also had to adjust the driver seat all the way back. The seat rail was a real pain and unavoidable, so I put a blanket down on the floor and put a small pillow on the seat rail for comfort. I also used a padded stool outside the vehicle for me to lay down as comfortably as possible. For reference, I'm a 5'8", 195lb, broad shoulder guy. I fit pretty snug, but I had enough room to move my arms around inside the cavity. The actuator is quite high in the cavity from this position, and was difficult to locate at first. The LED flashlight helped A LOT here. I'd recommend running the flex claw through the top and setting it near the actuator to give you some kind of bearing. You'll see the blend door actuator from here as well. The one you need is well above that. You will be able to see the actuator's electrical connection from this vantage point as well. The connector has a red piece on it (that may help you find the actuator). The bolt is very near the connector. When laying on your back and looking directly up at the connector the bolt will be to the left of the connector (towards the steering wheel). I used the same flex shaft, pivot adapter, nut driver bit contraption. You'll be able to fish the tool into the cavity using your hand. Try different paths around the steering column, pedals, and other connectors. I did this part without the drill attached and used the screwdriver, but this time it was on purpose. Trying to fish that tool through with the drill attached would be difficult.
6. The actuator is no longer held in. I used the long flat head screwdriver I had to pry the actuator out of its keyhole. I had to pry from the upper section. Then I had to get underneath near the brake pedal again to get the actuator out. Again, try different paths to get to the actuator. I was able to physically grab (almost palm) the actuator with a specific path, unfortunately I don't recall how I got around each thing. I lowered the actuator the best I could to not cross its electrical connection with any other connector. I eventually got it to the lowest point the electrical connector would let me (which was about level with the trim near the OBD connector). To remove the actuator's electrical connection, you will have to pull that red tab away from the actuator, then the connector comes out easily.
7. Now you're ready to install the new part. I originally thought, I'd do these steps in reverse order. Nope. Don't do that. I connected the electrical connector and tried to fish that actuator up the cavity. I scraped my hands, I got the actuator stuck for a good 15 minutes, and swore a lot. Easier way to do it: DO NOT CONNECT THE ELECTRICAL CONNECTION. Take the flex claw and insert it from the top, and fish it through to the lowest point in the cavity with the best possible path for the actuator to be raised. Attach the flex claw to the actuator (MAKE SURE ITS ATTACHED IN A PROPER ORIENTATION WITH THE CONNECTOR DOWNWARD) and raise it up with the claw. You should only have to minorly guide it through the cavity with your hands. Leave the actuator attached and in the upper part of the cavity near the place it's supposed to be installed. Route the electrical connector to the actuator. I had to disconnect the actuator, and use the flex claw to pull up the electrical connector. You may not have to do this. Either way, do what you have to do to get that connector attached to the actuator. PUSH IN THE RED TAB!
8. Now you'll have to align the stud with the keyhole. Of course mine did not line up with the screw holes and the keyhole. I turned on the car at this point, and lined up with actuator with its keyhole as best as I could. I then constantly switched from floor to panel vents to get the stud lined up correctly with the keyhole. Once the actuator seated in the keyhole, I still constantly switched from floor to panel vents until the actuator was lined up with bolt holes. It did eventually seat with the keyhole and the bolt holes. The temptation to not install the bolts washed over me lol. I figured this was a bad call. I decided to get the two upper bolts first because I was already there, and the actuator would be held just fine by these two for me to get the third. I installed these the same way I pulled them out: flex shaft, pivot head, magnetic nut driver bit. SUPER EASY. The third bolt was about the same challenge as it was to take it out, but the magnetic bit helped a lot for the installation. Honestly it took me about 15 minutes to get the three bolts in.
9. Time to test before putting it all back together. If it's functioning, install the instrument cluster with the 4 bolts. Make sure the electrical connection is installed. The trim is next, again make sure the electrical connection is installed. Finally the brake pedal trim. It took a little finagling to get it in, but it's the last step. Finish strong. 2 bolts, and you're done.
So that was my journey through this process. I did a lot of the trial and error for you, and found this to be the most effective way to accomplish the task. I don't know if you could find magnetic metric nut drivers, but that's one thing I would have done differently. I also would have gotten the flex shaft and pivot bit for the removal, instead of my ghetto 3/8 in. extensions and U joint. I hope this helps anyone with the same issue.