98 Explorer AC Blows Hot, even when off.

[jacques38]

1998 Ford Explorer XLT 4.0L.
So this issue has a little back story that may be relevant. At one point the AC was working great, ice cold air all the time, then one day it started blowing hot air. I switched the modes around and got hot air on every switch setting except for MAX AC. Running the AC on the MAX AC setting worked for a couple of months and then it quit working one day. Now every setting blows hot air and on top of that with EVERYTHING turned OFF heat is still seeping through the vents.

Now for the good part. Today I took apart the glovebox and removed the blend door actuator. It is functional when i turn the temperature knob. So that isn't the problem. Where should I look now?

 

[swetrid]

The physical blend door is broken and was very common on 2nd generation models. Dash removal and replacement of the heater box will be necessary unless you try some aftermarket kit.

 

[masospaghetti]

X2 on your blend door - not the blend door actuator. The top of the door becomes brittle and breaks.

You can replace the door without pulling the heater box by getting a replacement door from a local parts store (Dorman sells it, around $20) and cutting an opening in the bottom of the box using a hot knife or something similar. It's not a fun job, but its doable and definitely preferable to pulling the whole heater box. I've done this job twice.

This is the hot knife kit that I used - when I bought it a couple years back, it was made in the USA:

http://www.amazon.com/Dremel-1550-V...d=1412858641&sr=8-8&keywords=weller+hot+knife

This is Dorman's door kit, they actually have an attached replacement procedure exactly how it was described on this forum (the forum came first on this one!) Dorman states not to cut the "round pedestal" but I found it impossible to install the door without doing so, just don't cut it completely out and you should be OK.

http://www.rockauto.com/catalog/moreinfo.php?pk=3386019&cc=1119653

Replacement steps:

http://www.rockauto.com/info/RB/902-221_IS.PDF

 

[jacques38]

Alright thanks all will look into this now!