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Intermitant Restricted HVAC Air Flow to Cab

Brad1976

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October 3, 2011
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Year, Model & Trim Level
2002 Eddie Bauer Explorer
Hey all,

I had an issue with the "T" connector that attaches to the vacuum reservoir under the glove box falling off. The mechanic repaired it, but then I had an issue where every time I pressed the accelerator, I would hear a very loud sucking sound as though the vacuum system was sucking the air out of the resivoir. Even if I was cruising, released the peddle a little due to flow of traffic and then pressed a little further on it, I heard the sound... I took it back to my mechanic and he placed a Check Valve into the vacuum system (I'm not 100% sure where, just that it's there...) and the problem went away...

However it opened the door to a new problem... Sadly, I still haven't been able to pinpoint the problem... I researched the posts on air flow through the forums, and there are some really good suggestions, but none of them seam to fit my symptoms exactly so it'll still be a lot of trial and error for me. Thus why I'm hear in an attempt to save the time I don't have...

When the vehicle starts up everything runs perfectly and I have full air flow from the A/C. The HVAC (Eddie Bauer) automatically throttles down the blower motor as it should as the inside cab temp drops. Then, after a while I notice that the temp inside has started to creep up a little and I click in that the blower motor has increased speed as well, but sadly, there's next to no air coming out of the vents in the dash... I can manually select a different duct zone for the air to come out and there's no change. I can crack the temp tp the max of 31 degrees Celsius (Sorry, I have o clue about Fahrenheit) and yes, I can hear the air selector thing (brain fart at the moment on the part name) moving in the dash and the limited air coming out gets hotter. I drop the temp again and the air gets colder again. Even if I manually crank the blow motor speed to max, I can hear the blower motor cracking away at full speed and I can hear the sound of air moving, but it's just not coming out the ducts like it should and I have no idea where the air is actually going to.....

So far, the most probably cause I can think of could be something in the area of the Air Intake Duct on top of the blower motor, in behind the glove box. However, out of all the problems I've read so far, none of them have indicated an intermittent issue; they were all along the lines of no air at any time coming through the vents... Not to mention, when I manually select the "Re circulation" I can notice a change in both the sound of the air flowing, as well as the speed of the air flowing through the system, so I don't suspect that the infamous falling off blend door is the issue...

This is a little of an important to me to figure out as when I'm picking up my son and dropping him off to his mom's (yeah divorced...) the trip is about 20 min and my son was born with a genetic disorder resulting in that he was born with only one lung... If I have two lungs and hate being in a vehicle during a heat wave, I can only imagine what he feels like even though he never complains.....

I'm hoping not to have to take the entire dash apart like was suggested in the thread with a link to the guys blog where he was able to replace his Air Intake Duct in about 45 min, but I will if I have to... I'm also going away on EX with the military for the last half of August and I would love to have this fixed before I leave... In the short term, I'm planning to see if I can acquire one of those camera things that plumbers normally use to see down drains and pipes and fish it in starting from the centre ducts in the dash and see if I can find the blockage, but I'm not sure if I'll be able to get one, or even if...

In the mean time, I'm curious if anyone out there might have any suggestions.....

Thanks for reading and thanks in advance for any suggestions!
 






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