Dismiss Notice



Register Today It's free! This box will disappear once registered!

2002 Ford Explorer Blend Door Plastic Clip Broken Solution

Discussion in 'Stock 2002 - 2005 Explorers' started by mckeymouz, October 27, 2013.

^^Searches ExplorerForum.com^^
  1. mckeymouz

    mckeymouz New Member

    Joined:
    October 26, 2013
    Messages:
    1
    Likes Received:
    0
    Trophy Points:
    0
    City, State:
    Lousiana
    Year, Model & Trim Level:
    2002 Explorer
    I have a 2002 Ford Explorer and my climate control switch (the one that changes from air conditioner, defrost, heat, etc) would only blow out of the A/C vents regardless of what was selected.

    After a visit to a mechanic (who quoted me over $900.00 to fix), multiple visits to the parts store (all recommended replacing the actuator) and hours on google/you tube. I was at a loss. I did not want to have to remove the dashboard.

    Luckily while checking under the dash, I spotted a small broken plastic lever. When I switched the climate control switch, I could see the vacuum "piston" did indeed work, but the lever was broken.

    After multiple attempts with twist ties (thanks to google search), some washers and nuts... nothing seemed to work. Finally, I used a piece of foam roofing insulation to "transfer" she shape of the plastic (see photo). Using this, I took a piece of sheet metal and cut out a replacement piece. Additionally, I cut out a small piece for the back (note the slot to accommodate the plastic piece in the back).

    Then, using a 1 1/4" nut and bolt I assembled it back together. everything works fine now! (Except my knuckles... they are rather scratched up from the tight space!)

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  2. Support EF

    Join the Elite Explorers for $20

    Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


  3. tommyz

    tommyz New Member

    Joined:
    November 4, 2013
    Messages:
    5
    Likes Received:
    0
    Trophy Points:
    1
    City, State:
    Brooklyn, NY
    Year, Model & Trim Level:
    2004 Ford Explorer
    I had the same problem on my 04 explorer 36,368 miles. At 62 I can't do that work anymore, went to my mechanic (old school) found the part from Ford $279 ( upper half of chamber with all the doors). He removed the dash installed the new chamber. Total price $525. Everything works fine now. Won't have done it except for the low mileage.
     
  4. wbrudi28

    wbrudi28 Active Member

    Joined:
    May 16, 2010
    Messages:
    316
    Likes Received:
    1
    Trophy Points:
    18
    City, State:
    West Islip, NY
    Year, Model & Trim Level:
    2004 Explorer 4x4 XLT 4.0
    you dont need to remove the entire dash if you have a 3rd gen, and 4th gens are even easier with you not having to even remove the center console (panel is cut out of main dash on drivers side)

    motorcraft OEM replacement part purchased from amazon for $57 shipped. about to replace it this weekend. should only take an hour.
     
  5. icepickjazz

    icepickjazz Active Member

    Joined:
    February 9, 2008
    Messages:
    182
    Likes Received:
    2
    Trophy Points:
    18
    City, State:
    Noblesville, IN
    Year, Model & Trim Level:
    2004 XLT Sport 4.6L V8
    Can you supply the part number and or link?
     
  6. wbrudi28

    wbrudi28 Active Member

    Joined:
    May 16, 2010
    Messages:
    316
    Likes Received:
    1
    Trophy Points:
    18
    City, State:
    West Islip, NY
    Year, Model & Trim Level:
    2004 Explorer 4x4 XLT 4.0






We Support Our Troops!