97 Mountaineer PROBLEMS !!!

[geojim]

Hello all !
I'm new to your site and to be honest, I have recently purchased a 97 Mercury Mountaineer.
After a thorough test drive I offered 2000.00 to the private owner for a decent vehicle. A couple of minor rust spots, couple of cig. burns in seat, 125K on odometer but ran great and a 1 week old new PA inspection sticker. After leaving notary when money and title were exchanged the check engine light came on........as I expected it is O2 sensor. About 1 week later when weather warmed a bit I noticed heater only blew HOT air. I researched somewhat on internet and took to local stealership (Courtesy Ford, Altoona, PA). Dealer informed me worst case scenerio was true...bad blend air door and said 850.00 to replace plenum. Rusty is service mrg here and was VERY RUDE when I questioned price.
My mechanic buddy said he is familiar with these and offered to do job for 125.00 plus parts.

QUESTION : Is there really a way to replace door w/o removing dash/plenum ? I found just the new door on Ebay (item #8033721871 for 26.00 shipped).
Any tips or suggestions ?

Oh, driver's lumbar motor works but no inflate, rear hatch window doesn't open due to lock being messed up, drivers rear door lock stuck on child lock, noisy idler pulley, etc. I'm not complainiing too loud for a 2000.oo vehicle. LOL

 

[cgriffin_5139]

Hello all !
I'm new to your site and to be honest, I have recently purchased a 97 Mercury Mountaineer.
After a thorough test drive I offered 2000.00 to the private owner for a decent vehicle. A couple of minor rust spots, couple of cig. burns in seat, 125K on odometer but ran great and a 1 week old new PA inspection sticker. After leaving notary when money and title were exchanged the check engine light came on........as I expected it is O2 sensor. About 1 week later when weather warmed a bit I noticed heater only blew HOT air. I researched somewhat on internet and took to local stealership (Courtesy Ford, Altoona, PA). Dealer informed me worst case scenerio was true...bad blend air door and said 850.00 to replace plenum. Rusty is service mrg here and was VERY RUDE when I questioned price.
My mechanic buddy said he is familiar with these and offered to do job for 125.00 plus parts.

QUESTION : Is there really a way to replace door w/o removing dash/plenum ? I found just the new door on Ebay (item #8033721871 for 26.00 shipped).
Any tips or suggestions ?

Oh, driver's lumbar motor works but no inflate, rear hatch window doesn't open due to lock being messed up, drivers rear door lock stuck on child lock, noisy idler pulley, etc. I'm not complainiing too loud for a 2000.oo vehicle. LOL

Is there really a way to replace door w/o removing dash/plenum ? no
125 is a good deal get the door on ebay and your all fixed for 150 thats a good deal

 

[CDW6212R]

Ditto, I priced the whole AC box for just over $100, my good price. The hatch latch is easy and cheap to fix.

Worry about the engine stuff more, it can get out of hand if multiple things go out at the same time. Get a tune-up first, replace all front engine pulley bearings that are easy, the idler pulleys, plus belt. If you can make a decision about the condition of the cats, buy new O2 sensor. If it needs cats do that first. Good luck,

 

[95offroadx]

i have a parts mounty, pm with the stuff your looking for ill give you a killer deal

 

[CDW6212R]

There's a good answer, he is relatively close to you.

 

[dynamite196]

The blend door is an easy fix all you do is cut out the bottom of the heater box and pull the door out. Takes about an hour, I'll try and find you the link.

 

[Zulu95]

Do the heater core while you are in there. Much easier to do while the dash is out.

 

[johnindallas440]

1998 Ford Ranger Blend Door Replacement

Have you made it any further on the blend door replacement? I just bought the Dorman blend door repair kit from Napa for $10.99. Napa carries the part but the application data they have on their computer doesn't list any of the cars it fits. I got the Dorman part number from Rock Auto (Napa was able to cross to it) and found the application note on the Dorman site on how to use the assortment of parts that comes in the repair kits. There are two blend doors (to fit different models - you pick the one that fits), a metal template you temporary bolt to the top of the heater plenum to route out an access hole right above the door, and a replacement plate to cover the hole once you've installed the new door.

They don't go into any details on how to remove and replace the plenum.

I've found conflicting information on how much of the dash/instrument panel you've got to remove to get to the heater plenum depending on the manual I've checked out. In the Haynes manual you pull the instrument cluster, the radio panel, the passenger airbag, remove about four nuts from inside the engine compartment, disconnect the heater core hose and out it comes. Other manuals say pull just about everything off the firewall including dashboard, etc.

Has anyone done it this removal and replacement of the heater plenum and, if so, can you recommend a manual which accurately describes the procedure? I'll probably replace the heater core (I just replaced the radiator at 137K) while I'm in there.

If I do it I'll photograph the procedure and put it online.


Thanks John









http://www.dormanproducts.com/catalog/OESolutions2006/001-004AirDoorActuators.pdf

 

[johnindallas440]

Dorman Blend Door Repair kit.

I've taken some pictures of the Dorman repair kit (Dorman part 76807, Napa part BK 6601810). I'm not sure but it appears to have a beefier upper bearing surface (larger in diameter) than the stock ford part. It's hard for me to say for sure because I've only seen pictures of the OEM Ford part. The upper bushing surface of the Dorman door is about 0.655 inches and the repair kit comes with a replacement top plate for the heater plenum which has a bushing installed to receive the top blend door pivot point. I've taken some pictures and posted them at the link below. I'm still looking for a reference for an accurate R&R procedure for the heater plenum before I start tearing things apart.

Blend door pictures:

http://home.roadrunner.com/~richlandguitars/ford_blend_door.htm

Napa Part: This kit contains two blend doors and steel cutting guide for cutting a hole in the top of the heater plenum and a replacement top cover that has a new metal (instead of plastic) pivot bushing.

http://www.napaonline.com/MasterPag...10&Description=Heater+Blend+Door+Repair+Latch

Dorman part and application (scroll down to page four): The kit doesn't contain any explanation of what all the extra the stuff in the box is used for.

http://www.dormanproducts.com/catalog/OESolutions2006/001-004AirDoorActuators.pdf

Rock Auto has the blend door online for about 9 bucks and 7 bucks shipping.

http://www.rockauto.com/catalog/x,carcode,1315113,parttype,10640





John