defrost issues

[mkoppler123]

Hi I have an 02 explorer XLT with the manual heater controls. I just replaced the blend door actuator this evening because it would do the whole loud knocking thing when I switch from cold/hot. Well I've noticed before I replaced it that I would get very little air flow coming out of the dash or the side vents to defog the side windows. In fact when I have it on straight defrost I can still feel air coming out onto my feet. Same goes if I switch it to just the dash output, it still has air coming out onto my feet. So I'm guessing one of the vacuum controlled lines is probably to blame, but I'm not sure which one to look for? I see there's a red, yellow, blue, black and white hoses coming off the heater control knobs. Which line do I need to follow and checkout?

Also I did noticed what sounded like air leaking every time I switch the mode dial, could that be my problem? Other than this I get great heat output right now, so great that it about burns my right leg because the vent output is right next to it lol. Thanks

 

[BigRondo]

Welcome aboard!!

Do a search for that issue. There are a bunch of threads about it. I would post some of the threads, but I'm on my phone and it's not conducive to that sort of thing!!

 

[mkoppler123]

Good news is I found my problem, bad news the arm is broken from the door on the actuator with the yellow vacuum hose attached to it. So now I'm in the process of pulling the dash to get at it. Is this something that will require me to get a whole new assembly or should I be able to rig a fix for it? I did do a search and I found repairs for the fresh air door.

Also thanks for doing an excellent write up BigRondo, it really came in handy to replace a broken actuator, just a shame I didn't wait till after I removed the dash to swap it out...lol.