Is this the blend door actuator?

[gsmaclean]

I have a 2003 Limited with dual zone electronic climate control.

For a couple years now, in the winter, this has been happening: The truck has been driven and is warm, blowing hot air. It is then parked until it is cold-soaked (i.e. overnight). When the truck is started, the heating system, which was running, blowing hot air when the truck was last shut off, wants to shut off because it is blowing cold air until the engine warms up. So when the truck is first started up, the heating system makes a kind of groaning noise for a second or so.

I can get it to make this noise as well if I switch it rapidly from heat to cold or back.

This summer, I noticed that my truck wasn't getting very cold when the A/C was on. My wife however, was freezing. Investigating, I discovered that changing the temperature of the heating system from low to high, the passenger side would change from blowing icy cold air to super hot air - while the driver's side would change from blowing warm air to warmer air. I can't get extreme temperatures out of the driver's side like I can out of the passenger side.

So...the question is, is this caused by a blend door actuator? A blend door? What's the most likely suspect? And how tough is it to fix?

I've seen online tutorials for the manual heating system blend door actuator, but I'm pretty sure the dual-zone climate control will be different, as there will be two different blend doors (one for each side) - but I could be wrong about this.

My Haynes manual is less than worthless when it comes to this (no surprise there). So any help would be greatly appreciated.

 

[gsmaclean]

Just a bit more information: I ran the DTC self-diagnostics as described in this post. It did not show any errors.

It did however, actuate both the passenger and driver's blend doors - I could distinctly hear both of them actuating. I recorded the sound they made, which is better than me just calling it a "groaning" sound. Perhaps someone has heard this before?

Click here: Sound of my blend doors - opening and closing twice

 

[gsmaclean]

Nobody? Nobody has had this problem, or has an idea what might be causing it? Out of all the electronic climate control Explorers, I can't believe I'm the only one who has had this problem and figured out the fix.

 

[Exproblems]

It did however, actuate both the passenger and driver's blend doors - I could distinctly hear both of them actuating. I recorded the sound they made, which is better than me just calling it a "groaning" sound. Perhaps someone has heard this before?

Click here: Sound of my blend doors - opening and closing twice

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That doesn't sound like any bad blend door actuator I ever heard(would hear a clicking or clunking sound), but you may very well have a "Gremlin" living inside your vehicle and he sounds a little hungry. I have no idea what is making that noise.

 

[BigRondo]

Too me is sounds like 2 pieces of plastic rubbing/binding together. That might indicate that the blend door is binding.

When I first heard it I had to fight off the instinct to grab a rifle.

 

[Exproblems]

When I first heard it I had to fight off the instinct to grab a rifle.

>>>>>>>>>>>>>>>

Easy BR, it's just a flash back to your military days. LOL, it does sound like a rabib animal and I do have a few skunks and racoons running around the backyard at night. BTW BR, did you hear about the new players the Bills recently signed? Mario Williams from Houston and Anderson from your Pats. Both pass rushing specialists. The heat is coming Bradys way. He is going to pay for that Buffalo hotel remark he made. Also, the Sabres just might make the playoffs. Big game tonight for 8th playoff spot, Sabres vs Capitols at 7pm.

 

[BigRondo]

>>>>>>>>>>>>>>>

Easy BR, it's just a flash back to your military days. LOL, it does sound like a rabib animal and I do have a few skunks and racoons running around the backyard at night. BTW BR, did you hear about the new players the Bills recently signed? Mario Williams from Houston and Anderson from your Pats. Both pass rushing specialists. The heat is coming Bradys way. He is going to pay for that Buffalo hotel remark he made. Also, the Sabres just might make the playoffs. Big game tonight for 8th playoff spot, Sabres vs Capitols at 7pm.

Bruins & Lightning tied at 1 with 5:36 left in first. Pats have made some signings as well!

 

[Exproblems]

Bruins & Lightning tied at 1 with 5:36 left in first. Pats have made some signings as well!

>>>>>>>>>

Watching the NHL channel highlights right now. See the Bruins won that game 5-2. Sabres smoked the Caps 5-1, Goalie Miller outstanding, own 8th playoff spot for now, 5 games left. Yes, I see the Pats signed some WR's, didn't hear of any lineman yet, but heard Matt Light may retire. If he does, gonna hurt Bradys protection some. I see Oocho-Stinko (WR Johnson) decided to stay with the Pats. His career went down the tubes since he became a Pat, 15 catches all of last year and 1 TD. Can't believe a show boating, ego maniac like him can handle not being the center of attention anymore. I kind of like not hearing his name mentioned anymore. If you can't already tell, I don't care much for him or players that act like he did on the field. That includes Bills WR Steve Johnson, that idiot cost us a game last year on a penalty he took for excessive celebrating a TD he scored. He took a lot of heat for his antics, so I'm hoping it is out of his system come this season. BTW, just to keep this on an automotive topic, I had my mechanic change my Rear diff Pinion seal and while he was at it, had both front stabilizer bar links replaced under my aftermarket warranty yesterday. I just had lower spine surgery 3 weeks ago (Stenosis removed), so I wasn't up to tackle that work myself yet. Gettin there though, started back at the gym last week.

 

[BigRondo]

Yeah, I hate the showboating too. Maybe this year he can learn the playbook. :

gsmaclean, sorry about the hijack. Any update on your issue?

 

[gsmaclean]

Too me is sounds like 2 pieces of plastic rubbing/binding together. That might indicate that the blend door is binding.

When I first heard it I had to fight off the instinct to grab a rifle.

I agree, sounds like something binding - but with no documentation or idea where the blend door is in a climate control system, or how to get to it, I'm reluctant to start tearing things apart. I know there are two blend doors, one each for driver and passeneger.

 

[BigRondo]

I will check my shop manuals tonight when I get home and see if I can scan some info for you. My manuals are for the '02 but should be relevant.

 

[Exproblems]

I agree, sounds like something binding - but with no documentation or idea where the blend door is in a climate control system, or how to get to it, I'm reluctant to start tearing things apart. I know there are two blend doors, one each for driver and passeneger.

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I know on the manual control system, the temp blend door itself is inside of the black plastic box located behind the lower center console area and have found photo's of it here in this forum. Did you try searching for posts in here using the "search function window" at the top of the web page looking for photo's of the "dual climate control temp blend door"? Type your search question in there and see what comes up.

Update: I found some old posts you might want to look thru at the link below. The blend door fix listed there is for older model Explorers, but some people with 2003's had questions pertinent to your year vehicle. Don't know if they had the dual climate controls either. It sounded to me from reading some of the posts there, that the 2003 blend doors are quite hard to get at. Here is some quotes from them below:

http://www.explorerforum.com/forums/showthread.php?t=214332

Kicker55 asked- Post # 18- someone mentioned that the 03 expl . you cant get to the blend door or accuator is this true? If not does anyone know where the exact location of the control. thanks kicker55

Moke 210 asked- Post # 50-- Hello. I have a 03 ford explorer sport trac and the blend door is shot. The people i talked to said I had to remove the whole dash board to get to the blend door. Is this true or is there some type of short cut I can use. Thanks for the help.

Just found another 2003 Explorer post from that web link. It is from post #2:

>>>>>>>>>>>>>just to let folks know the 2003 ford explorer has had the blend door location moved so that it sits horizontaly behind the center console and as best I can tell Can't be changed. any help would be great. >>>>>>>>>>

 

[Exproblems]

I agree, sounds like something binding - but with no documentation or idea where the blend door is in a climate control system, or how to get to it, I'm reluctant to start tearing things apart. I know there are two blend doors, one each for driver and passeneger.

>>>>>>>>>>>>>>>>>>>>>>>>>

Here is another web link for you with dual climate control info: Just making up for the "hijacking"!



http://www.explorerforum.com/forums/showthread.php?t=198271&page=5

From Page 5, Post # 81 of the web link above. This is from a person who owns a 2002 model XLT. Might help you with your 2003 Explorer. Check this post out, there is more technical info there on the dual climate control system.

From Post #81>>>>>Yep, there are 2 blend doors and 2 actuators with the DATC. The one on the left is what is shown in this thread and your's has one in the same place. Your's also has one on the right side that looks like a holy terror to get at. The FSM shows the whole dash assembly being "positioned aside" to get to it.
But, does it sound logical that both blend doors would be only going part way to heat on both sides at the same time? Sounds to me like something else is wrong, maybe one of the sensors is giving bad input to the DATC module. It gets input from the cabin air temp sensor, the ambient air temp sensor, the sun load sensor, and the PCM. The DATC module can store 2 types of codes from all the input sensors except the PCM. Don't ask me why Ford calls hard fault codes "on demand" and intermittant fault codes "continuous", but they do. So see if any codes are stored:>>>>>>>>>>>>>>>>>>>

 

[gsmaclean]

Thanks ExProblems. I actually found those threads before as well (I did search for and read through a LOT of threads before I posted). The first one had pictures at one time, but no longer, unfortunately. The second one I already tried (the DTC check) as I mentioned in my original message.

Still any suggestions anyone might have, I'm more than open to!

 

[Exproblems]

Still any suggestions anyone might have, I'm more than open to!

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Your welcome and I'm tapped out for now. I've got the same Haynes manual as you do, so not much I can look for in there to help you. If I find anything new in the forum, I'll get back to you. Kind of glad I don't have the digital, Dual Climate Control system in my Ex. Seems like it can be a real PITA to deal with when a problem pops up with it!

 

[BigRondo]

I am in the process of scanning info for you dealing with the dual climate control. It is a tedious undertaking due to the difficulty getting the manuals to sit correctly on the scanner.

 

[gsmaclean]

I am in the process of scanning info for you dealing with the dual climate control. It is a tedious undertaking due to the difficulty getting the manuals to sit correctly on the scanner.

Thanks so much. I know exactly what you're talking about, as I scanned the 1000+ page service manual for my motorcycle the same way, so that I could have an electronic copy with me in my phone on the road in case I ever needed it. I don't want to ever do that again!

 

[Black Dynomite]

I have this same sound every time I turn on my AC.

 

[RKelly2233]

gsma... dear god please tell me your kidding... i have that EXACT NOISE in my aviator. its whenever I change the hvac direction! whenever the ac/heat is on it blows to the floor (in addition to the defrost or upper vents). i think im gonna have to take it in to the stearship some day to have the guys listen to it. my explorer needs a blend door i think, but its not the electronic one- and ill do it soon (thanks in advance bigrondo)- but no one seems to be able to help with my monster of an aviator...

 

[bore_pig]

Did you ever get this noise figured out? My mountaineer makes the same sound and also has the lukewarm heat like a bad blend door actuator. I have the new actuator, just wondering if I need to purchase more parts to get everything fixed in one shot.