Broken AC vent door arm

[Diyflmech72]

As I've seen throughout several forums, many owners have described issues where the air blows out of the defrost, even when the knob is turned to Max AC.

First you need to check the lever arm connected to the actuator. To do this, you need to open the glovebox and depress the side tabs to drop it down. Next look through the glovebox opening towards the stereo and upward. You're looking for something like the picture. If the metal arm is not connected to the lever, this is causing the issue described.

Never fear, there is a solution! Both solutions are offered by the same guy.

The first solution is for those with 3D printers.

2004 Ford Explorer Blend Door Lever Fix by seanauff

UpdateThe all plastic (PLA) version of this part that I was using (19A574_fixpart v8.stl) started to break after ~100 cycles. It still continued to function, though (see pictures). Still, I replaced it with the recessed nut version printed with PETG. I recommend not using the all plastic version...

www.thingiverse.com

The second solution is purchasing it.

Ford Blend Door Lever Repair Kit - Etsy

This Car Parts item by seansparts has 68 favorites from Etsy shoppers. Ships from Littleton, CO. Listed on Apr 14, 2024

www.etsy.com

Hope this helps.

 

[07EddyB]

I drilled a hole in what was left of the tang and reattached the actuator arm with a tie wrap. Knowing that I had moved the attachment point and that could cause an issue, I tightened it up while it was running with the actuator in the retracted position. Just snugged the tie until the door was fully closed. That leaves a little slack in the connection but keeps it from putting too much pressure on the arm in either position.

 

[Diyflmech72]

I drilled a hole in what was left of the tang and reattached the actuator arm with a tie wrap. Knowing that I had moved the attachment point and that could cause an issue, I tightened it up while it was running with the actuator in the retracted position. Just snugged the tie until the door was fully closed. That leaves a little slack in the connection but keeps it from putting too much pressure on the arm in either position.

I wasn't too keen on that idea just in case there wasn't enough material left to keep from stressing the plastic and essentially going through the same issue. I put this out there for anyone wanting to repair this as close to original as possible.

 

[Blackhawkxx]

Never fear, there is a solution! Both solutions are offered by the same guy.

That part is listed for a 2004, is it the same as 2006-2010? Either way, thanks for posting that as it is great info to know.

 

[Diyflmech72]

That part is listed for a 2004, is it the same as 2006-2010? Either way, thanks for posting that as it is great info to know.

That part is listed for a 2004, is it the same as 2006-2010? Either way, thanks for posting that as it is great info to know.

Sean sent me 2 of them and I placed them back to back with a longer screw. It was to fill the large space between the end of the arm and the housing. I haven't updated him on that yet. But it is fully functional and not rigged with a zip tie, which could eventually fail from friction.

 

[SGBlackjack]

As I've seen throughout several forums, many owners have described issues where the air blows out of the defrost, even when the knob is turned to Max AC.

First you need to check the lever arm connected to the actuator. To do this, you need to open the glovebox and depress the side tabs to drop it down. Next look through the glovebox opening towards the stereo and upward. You're looking for something like the picture. If the metal arm is not connected to the lever, this is causing the issue described.
View attachment 323512

Never fear, there is a solution! Both solutions are offered by the same guy.
View attachment 323513
The first solution is for those with 3D printers.

2004 Ford Explorer Blend Door Lever Fix by seanauff

UpdateThe all plastic (PLA) version of this part that I was using (19A574_fixpart v8.stl) started to break after ~100 cycles. It still continued to function, though (see pictures). Still, I replaced it with the recessed nut version printed with PETG. I recommend not using the all plastic version...

www.thingiverse.com

The second solution is purchasing it.

Ford Blend Door Lever Repair Kit - Etsy

This Car Parts item by seansparts has 68 favorites from Etsy shoppers. Ships from Littleton, CO. Listed on Apr 14, 2024

www.etsy.com

Hope this helps.

This part broke in my 2005 Explorer. How hard is it to replace with the one recommended above? Specifically, when you install it can it rotate so that you can place the pin part back on the actuator without causing the bent plastic part stress?.

Thanks!

 

[Diyflmech72]

This part broke in my 2005 Explorer. How hard is it to replace with the one recommended above? Specifically, when you install it can it rotate so that you can place the pin part back on the actuator without causing the bent plastic part stress?.

Thanks!

I actually had to epoxy the part in place and I removed the part with the cutout for the arm. That one portion made it extremely difficult to attach the arm because of the lack of maneuverability in the dash. Other than that issue, it works well.