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Heard a pop & a flap slap shut, now air flow is very weak

Discussion in 'Stock 2002 - 2005 Explorers' started by Marble68, May 31, 2018.

^^Searches ExplorerForum.com^^





  1. Marble68

    Marble68 New Member

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    City, State:
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    Year, Model & Trim Level:
    2003 Ford Explorer LTD
    Hi all -

    First, I'm new to the forum and not the most knowledgeable about working on the climate system - so i please ask for your patience and forgiveness my ignorance in advance.

    I've got a 2003 Ford Explorer with dual automatic air control.

    Yesterday, I had the AC on full blast, and I heard a pop and a vent slam shut. Air flow from the vents all but ceased. Some air still comes out, but not much. I can change it from heat to cool and nothing changes. Also, neither does defrost or floor alter the volume of air that's moving.

    What should I check? Maybe a vacuum hose came off, or a pin on an actuator broke? I don't know where to look.

    I've opened by glove bock and dropped it down - and I see a large black blower motor.

    I'm in Texas and we're looking 100+ temps all next week, so my goal at this point is just to get the air flowing! haha

    Any tips, advice, or links are most appreciated.
     
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  3. sfhess

    sfhess Member

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    Year, Model & Trim Level:
    2002 Explorer XLT RWD V6
    Fresh air door broke and fell, blocking the blower motor intake. Do a search for "fresh air door" and you will find lots of help.
     
  4. WaterBrat

    WaterBrat Member

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  5. mountaineer2004

    mountaineer2004 Elite Explorer

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    Mine fell down a while ago, so I cut a hole in the HVAC mesh to remove it.
    When Winter arrived, cold air leaked in, so I just put tape around the mesh.
    I'd like to replace it, so I can use the re-circ feature in Summer.
     
  6. WaterBrat

    WaterBrat Member

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    At the end of the thread refereced above I listed how I replaced the door. Activate the recirc button first so you can verify the movement of the lever. This spring when I did it a second time to glue the pin on, I found that removing the metal brace ( #14 in the illustration) made it a lot easier to get to the bolts holding the vac canister. Also know the activation lever needs to be attached to the pin when the pin is inserted. **** Important to note if putting glue on the pin****
     
    Last edited: May 31, 2018
  7. mountaineer2004

    mountaineer2004 Elite Explorer

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    ^^^ I'll look at that ... thanks.
     

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