How to: My take on the blend door fix for 95+ Explorers (several pics)

[Opera House]

Question on door failure

My understanding from your explanation and picture is that the keyway that the actuator fits in fails. When the plastic cracks, is the door still retained in the bushing and allowed to swing freely or does the door drop down and get stuck?

I am asking this question because my 97 has this problem and is stuck in the AC position. Trouble is I got my 92 apart with some engine work and I will be rebuilding the A4LD myself. So I'm booked for a little while. I'm thinking of cutting a hole in the box and physically moving the door till spring when I have time. Does this sound like a plan? I should probably order the box now so I have a model to work from.

 

[X24]

I have heard of people doing that. They go in from behind the glove box and move it with a coat hanger. Then they just tape up the hole.

 

[jjue]

You are right about the keyway. However, the door will swing freely, but fromthe design, it will sit in one direction or the other.

 

[bates]

alright ill be the dumb one, what was all this for? i see the plenum but what was the benefit of all this?

 

[Robb]

Originally posted by bates
alright ill be the dumb one, what was all this for? i see the plenum but what was the benefit of all this?

The blend doors go bad and the AC will only work in MAX. Any other position, you get heat.

Robb

 

[bates]

ahhhhhhhhhhhhhh ok that would suck!
thank you, i feel more intelligent now.

 

[jjue]

OK, I feel kinda dumb about my 2 problems after fixing the blend door. I didn't fully disconnect one wiring harness on the passenger side of the dash, leaving not much audio on the other 3 speakers. Then, the dash light problem was fixed by working with the new dimmer rheostat that I bought to replace the original one that died. Now I have adjustable illumination once again. I managed to find this out before pulling the dash for a second time.

 

[BoatsRcool]

i drove a car today with this problem, it will deffiently be fixed before i get anywhere near buying it, but will the MAX a/c always work, or will the problem eventually take it away too?

 

[X24]

Originally posted by BoatsRcool
i drove a car today with this problem, it will deffiently be fixed before i get anywhere near buying it, but will the MAX a/c always work, or will the problem eventually take it away too?

before mine was fixed I only got outside air on max a/c.

 

[jjue]

Max A/C will always work, but if you travel long distances, be prepared to dress warmly if you don't get it fixed.

 

[wpurple]

I am going to pray that my 97 blend door never breaks....but if it does, Did FORD fix the problem with a new type door that will not break?? Is there a part number for a new replacement door?
If so, I am curious how the new door differs from the ols one.

 

[X24]

I'm pretty sure the problem with the defective one is that, during manufacturing, they put the wrong door in. They used the one for the auto climate control with the manual control setup. The door was not the right size and falls over causing it to jam or break. The replacement has the right door in it.

This is what Ford told me.

 

[codycr6]

blend door

So is this a problem with Explorer's with the automatic climate control ? I have a 1997 Eddie Bauer V8 2WD with climate control...and have been worried about this problem. I just bought mine two weeks ago, and love it so far. I am going to do a thorough inspection of the front end, put on new shocks, and do a brake job in the next week or so. I allready lowered the front, added ventshades, and started putting in the wiring to add to the JBL stereo.

 

[wpurple]

So by the description of the problem blend door, it can happen at any time, age of the Explorer should have no effect. It is the wrong part and it is just Russian Roulette to when it fails??

-K

 

[jjue]

The correct part number for the manual climate control blend door is F87Z-18471-DA. Yes, the problem is that they (Ford) used the wrong plenum.

 

[Opera House]

So is it still possible

To get just the blend door instead of the whole new plenum box? Is there some source with old stock? I cut a hole and was able to reach in and move the blend door with my hand. Got the feeling that I could bend it out and do the replacement like those AC guys did by going through the engine side. Don't want to crack a door out of a $100 new box.

 

[Robert]

There are two different reasons for the blend door failure. One is as was mentioned, Ford put the wrong blend door in on some Explorers. The other issue is that the firsts several years had a plastic blend door. The plastic gets brittle over time and the part the rod connects to, breaks off. Ford started using a nylon door in either '98 or '99 so it stays much more flexible and doesn't dry out and crack.

 

[wpurple]

Is there a TSB on the blend door?

 

[wpurple]

So, when you have a bad door, what do you replace, the door or the door and plenum?

 

[wpurple]

Heating & Air Conditioning Occasional problems on this vehicle are failures of the Heater Case and Blend Door.The cost to repair the Heater Case and Blend Door is estimated at $105.00 for parts and $273.00 for labor. All prices are estimates based on $65 per flat rate hour and do not include diagnostic time or any applicable sales tax.

Quoted from MSN carPoint