Hope you never have to see this

[booner]

Had to replace both the fresh air vent door as well as a servo and the door that controls defrost/floor air. Total cost of parts, 260 dollars and 10 hours of labor. Thankfully, the labor was done for free by my dad, a retired Ford technician/service manager. He couldn't believe how cheaply the original parts were made.

 

[BradR]

May I be the first to say, F THAT? lol.

You have an awesome dad!

 

[Joe Dirt]

I think I'd light a small campfire on the floor in a pie tin before doing that! Good GOD!

 

[booner]

Yeah, he hated doing it and said all his mechanics have always hated pulling the dash. My dad rocks for sure.

 

[cattleshow]

WOW--I think my timing chain replacement job was easier than that.
Are the replacment parts BETTER made. I sure hope so.
Is this a common problem.? I hope not.
What vehicle was it.?

 

[booner]

From what I have read, there are a lot of folks out there with at least 1 or both problems. The replacement parts I bought had a bit more reinforcement to the weaker areas and it appears they will be able to stand the test of time. The work was done a 2005 Explorer XLT.

The truck had no heat at all coming from the vents. At first, we jury rigged it with zipties to keep the defrost/floor door open so we could get some heat. Later on, I noticed cold air coming through the glove box and we determined the fresh air door was broken. Pasted below are 2 threads describing my problems.

http://www.explorerforum.com/forums//showthread.php?t=230670

http://www.explorerforum.com/forums//showthread.php?t=255578

 

[BobWiersema]

This is why my new blend door servo motor is still in the box. It has been since last May and most likely will remain there for a while.

 

[corkey]

looks like alot of curse words there,

 

[techieman33]

If I ever have to open mine up I'm replacing everything I can get too

 

[cattleshow]

This is why my new blend door servo motor is still in the box. It has been since last May and most likely will remain there for a while.

WOW-What a job. It used to be a simple cable to do the same thing. The door was metal and the whole assembly was forever.(in the old days) .Now it takes a cheap plastic Blend door as they call it (fancy fancy) and a servo motor to do the same thing. Drives me nuts how difficult it has become to work on vehicles.. Pulling a cable in and out wasn't really that hard.
Ive learned to expect anything on todays vehicles. Engineers ,you got to love them.

 

[Turdle]

I hope is was not a mere vacuum leak which caused defrost vent only-

http://www.explorerforum.com/forums/showthread.php?t=192842

You might want to get the heater core while you are in there.
I too pulled a dash once. Can't say it was very fun.

http://www.explorerforum.com/forums/showthread.php?t=173650&highlight=Heater+core

 

[booner]

Definately not a vacumn leak, parts were broken and the actual door was broken as well. Hope the heater core is alright, as the dash is back in place. Heat is working extremely well now.

 

[booner]

Oh yeah, Turdle, we had no heat at all coming from the floor, vents, or defrost. Dad used some zipties to keep the door open so we could have defrost and floor heat while we waited for the parts to come in.