Blend door fixed..... Alot of work, but worth it... PICS

[Jamieh560]

I took about 8 hours to replace my plenum.... I agree with everyone about how much it SUCKS but it saved about 800 buck....To replace the plenum you have to remove the center console, dash, and loosen the evaporator housing. Refer the your shop manual to remove dash.. If you have any problems pm or IM me ( Jamieh560 ) Save yourself alot of money by doing it your self!!!!

 

[Jamieh560]

Here's the old and new plenum

 

[Garth]

Lots of red Xs.

 

[Jamieh560]

Here shows where the blend door broke

New plenum installed

Just like new..... I have heat now.....YES

 

[Turdle]

Any way to get these pics posted?

 

[Jamieh560]

Okay I think the pictures work now.... Sorry about that guys!

 

[Turdle]

First I must commend you on getting out the camera and actually using it while you worked. I know it is a hassle.
I wish however, that you would have included more pics of dash removal steps, and the evap housing-plenum replacement.
do you have those?
Not asking much am I?

 

[410Fortune]

Is the new plenum updated so the part wont break again?
Mine looked just like that, except I used the old piece of a nail through the actuator trick, worked just fine and I fixed it in 20 minutes upside down under the dash.

You did it the RIGHT way
Nice work!

 

[Jamieh560]

Yeah the new plenum is made better... Comparing the two the new blend door feels like its made from a better plastic... Ford told me it wouldn't break again... Also Ford want 168 bucks for the plenum..... I agrued with them about 5 minutes and got it for 90 bucks after tax....

 

[410Fortune]

$90 hua? Good for you!
They should be free IMO, especially when the customer is doing all the work!

Hey think of it this way now you KNOW how to pull your entire interior apart, on a Gen II that is no easy task!

 

[SkanlaxJMO]

Great job

 

[whitemage25]

How long did it take to get all the way down to bare firewall like that? I'm thinking about throwing Dynamat on there but it looks like a daunting task.

 

[Mbrooks420]

I knew it was a full day of work, but I didn't realize the wheel and column had to come off. I was going to attempt this in the spring. I still have heat and AC but it is either full hot or full cold. I'm going to pull the seats, but it looks like I am in for more than I feared.

 

[CDW6212R]

Congrats. Did you mean that the whole box was from F.ord for $90? My 98 model does some weird things, and I haven't checked the blend door yet. Regards,

 

[Jamieh560]

Its not that bad honestly..... Its more time consuming than anything.... I probably took 4-5 hours to get the the fire wall..... I got the pelium from ford fr 90 bucks after arguing with them awhile...

 

[Mbrooks420]

Anything special required to pull the steering wheel/column besides a wheel puller?

 

[CDW6212R]

Leave the steering wheel attached, there are four main bolts under the column, etc.

 

[Jamieh560]

You just unhook steering shaft( 1 bolt), Shift cable, dissconnect wiring harness, and remove 4 bolts.....

Heres another link really good thread on this issue

http://www.explorerforum.com/forums/showthread.php?t=59787&highlight=blend+door+fix+pics