This is my how to for replacing the blend door actuator on the 3rd Gen Ex. The Blend Door Actuator controls the hot/cold temperature in the vehicle, not where the air is blowing from or fresh air/recirculated air. While researching this issue I found several discussions, but no definitive how to. I used this post as a guide:
3rd gen Explorer Blend Door Actuator Replacement. Even with this excellent post by
ColdnFrosty, I was “flying blind”. That has lead us to this write up.
I purchased the Blend Door Actuator from my Ford Dealer. Cost was $70.00.
I recommend purchasing it at the dealer as others have had problems with the ones purchased at auto parts stores.
VIN is required to ensure you get the proper part.
This procedure involves cutting the dash. The part of the dash I cut out is not visible with the center console back in the Ex. Some have replaced the actuator without cutting the dash. Whether or not you cut the dash is a decision you will have to make. I AM NOT RESPONSIBLE FOR ANY DAMAGE OR UNWANTED MODIFICATIONS YOU DO TO YOUR VEHICLE. YOU ASSUME ALL RESPONSIBILITY FOR CUTTING YOUR DASHBOARD. ATTEMPT THIS INSTALL AT YOUR OWN RISK.
Be Sure To Check Out My Other Write-Ups:
How To: Remove/Replace 3rd Gen Door Panel
How To: Install Signal Mirrors On 3rd Gen Ex
How To: Restore Faded, Yellowing Headlights
How To: Replace Multifunction Switch in 3rd Gen Ex
How To: Paint Rear Pillar Trim
How To: Replace 3rd Gen Ambient Air Temperature Sensor
How To: Test a Relay
How To: Remove/Replace 3rd Gen Center Console
Tools Required:
1. 7MM Socket
2. 8MM Socket
3. 10MM Socket
4. 10MM Deep Socket
5. Socket Driver Handle
6. Ratchet
7. Extension
8. 8MM Box-End Wrench
9. Utility Knife
10. Large Slotted Screwdriver
11. Butter Knife of Putty Knife
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Parts Required:
1. Blend Door Actuator
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2. Electrical Tape
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Blend Door Actuator Replacement Detailed Instructions:
1. Remove Center Console Upper Half
1.a. Remove rubber mat
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1.b. Remove screw under mat – 7MM socket required
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1.c. Pry from rear and pull out console upper half
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1.d. Disconnect front power point connector & extra power source connector (Cigarette Lighter?)
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1.e. View with upper half removed
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2. Remove Center Console Lower Half
2.a. Disconnect rear power point connector
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2.b. Pop off rear power point connector with screwdriver – be careful not to damage connector
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2.c. Pop off harness with screwdriver – be careful not to damage any wires
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2.d. Remove 2 front screws – 8MM socket required
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2.e. Remove 2 duct screws – 8MM socket required
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2.f. 4 top screws remain in place
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2.g. Remove passenger side rear screw cover – butter knife or putty knife required
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2.h. Remove passenger side rear screw – 8MM socket required
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2.i. Remove driver side rear screw cover – butter knife or putty knife required
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2.l. Remove driver side rear screw – 8MM socket required
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2.j. Pull passenger side front of console away from center and toward door to disengage velcro
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2.k. Pull driver side front of console away from center and toward door to disengage velcro
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2.l. Lift console lower half up and out of vehicle
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3. Remove Lower Dash Panel
3.a. Remove 2 bottom screws – 7MM socket required
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3.b. Pull from top
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3.c. Clip may come off - No worries it can be put back when panel is reinstalled
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3.d. View with panel removed
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4. Remove Dashboard Brace
4.a. View of dashboard brace
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4.a. Remove top screws – 10MM socket required
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4.b. Remove bottom nuts – 10MM deep socket required - Pull carpet back to reveal bottom nuts
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4.c. View with brace removed
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5. Remove Lower Heater Duct
5.a. Pop off harness with screwdriver – be careful not to damage any wires
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5.b. Remove 2 screws – 8MM socket required
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5.c. Wiggle duct out – it seems like it won’t come out but it will – pull front of it down
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6. Remove Blend Door Actuator
6.a. Locate top screw - Arrow indicates area to look for top screw
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6.b. View of top screw
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6.c. Remove top screw – 8MM socket & 6” extension required - Picture shows how to access top screw
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6.d. Locate bottom rear screw - Arrow indicates area to look for bottom rear screw
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6.e. View of rear screw
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6.f. Remove rear screw – 8MM box-end wrench required -
Ratcheting box-end wrench will be easier but not required
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6.g.1. Locate bottom front screw - Arrow indicates area to look for bottom front screw
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6.g.2. Locate bottom front screw - Red dot indicates approximate area of bottom front screw
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6.h. View of bottom front screw
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The following steps involve cutting the dash. Some have removed the old actuator and replaced the new one without cutting the dash. I recommend trying without cutting the dash and only cut the dash if the actuator cannot be removed and replaced with the dash intact.
6.i. Cut dash – Utility knife required –
WARNING ATTEMPT AT YOUR OWN RISK - Arrows indicate area of dash to be cut
View attachment 234309
6.j. View of cut dash with foam removed - Cut vinyl then remove foam with utility knife
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6.k. Remove back plastic - Cut remaining plastic with utility knife - Red arrows indicate area to be cut - White arrow indicates bottom of Blend Door Actuator
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6.l. View of cut dash to reveal bottom front screw
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6.m. Remove bottom front screw – 8MM box-end wrench required -
Ratcheting box-end wrench will be easier but not required
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6.n. Wiggle out the blend door actuator - Red arrow indicates shaft - White arrows indicate direction to pull first: away from heater box - Yellow arrow indicates direction to wiggle Blend Door Actuator out
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6.o. Turn actuator so shaft it facing upward
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6.p. Disconnect blend door actuator - Arrow indicates tab to be press to release connector
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7. Install New Blend Door Actuator
7.a. Connect actuator
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7.b. Turn ignition key to run position
7.c. Rotate temp selector from cold to hot to verify operation of actuator – shaft should be moving
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7.d. Rotate temp from hot to cold setting – shaft should be moving – leave temp set to cold
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7.e.
Wait for shaft to stop moving! Then turn ignition key to off and remove key -
LEAVE TEMP SET TO COLD
7.f. Wiggle actuator into position – this takes some patience – be careful not to damage shaft - Shaft is keyed and will only go in one way -
DO NOT FORCE SHAFT - Red arrows indicate direction to wiggle in Blend Door Actuator - White arrow indicates where shaft is inserted
View attachment 234320
7.g. Install bottom front screw – 8MM box-end wrench required –
Ratcheting box-end wrench will be easier but not required - start threading with fingers then use wrench –
DO NOT OVER TIGHTEN
View attachment 234321
7.h. Install bottom rear screw – 8MM box-end wrench required –
Ratcheting box-end wrench will be easier but not required - start threading screw with fingers then use wrench –
DO NOT OVER TIGHTEN
View attachment 234322
7.i. Install top screw – 8MM socket & 6” extension required
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7.j. Tape screw to socket
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7.k. Start threading screw
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7.l. Pull extension out
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7.m. Reach up and remove socket - Arrows indicate where to reach up to remove socket from screw
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7.n. Remove tape and replace socket
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7.o. Tighten top screw –
DO NOT OVER TIGHTEN
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8. Test Blend Door Actuator
8.a. Start vehicle and let it reach normal operating temp
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8.b. Set selector to vent (engine must be running since this operates on vacuum)
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8.c. Temp setting should be on cold
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8.d. Turn fan on
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8.e. Test temp of airflow – it should be cold
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8.f. Rotate temp setting all the way to hot
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8.g. Test temp of airflow – it should be hot
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8.h. Nice job! You are now ready for winter
8.i. Turn vehicle off
9. Reinstall Lower Heater Duct
9.a. Wiggle duct into place - Arrows indicate position to wiggle in duct
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9.b. Install 2 screws – 8MM socket required
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9.c. Push harness into place
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10. Reinstall Dashboard Brace
10.a. Install 2 bottom nuts – 10MM deep socket required - Pull carpet back for access
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10.b. Install 2 top screws – 10MM socket required
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10.c. View with brace reinstalled
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11. Reinstall Lower Dash Panel
11.a. Set panel in place and push in top section
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11.b. If clip fell off, then replace clip
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11.c. Install 2 bottom screws – 7MM socket required
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12. Reinstall Center Console Lower Half
12.a. Set console lower half back into place
View attachment 234346
12.b. Push console forward to close gap in lower duct
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12.c. While pushing console forward, Install passenger side rear screw – 8MM socket required
View attachment 234348
12.d. Replace passenger side screw cover
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12.e. While pushing console forward, Install driver side rear screw – 8MM socket required
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12.f. Replace driver side rear screw cover
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12.g. Install 2 duct screws – 8MM socket required
View attachment 234352
12.h. Install 2 front screws – 8MM socket required
View attachment 234353
12.i. Push passenger side front of console toward center to engage Velcro
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12.j. Push driver side front of console toward center to engage Velcro
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12.k. Push harness back into place
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12.l. Push rear power point connector back into place
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12.m. Connect rear power point
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13. Reinstall Center Console Upper Half
13.a. Connect extra power source & front power point
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13.b. Set console lower half back into position and push downward to snap into place
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13.c. Install screw – 7MM socket required
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13.d. Replace rubber matt
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14. Blend Door Actuator Replacement is Complete!
14.a. View of cut dash with console installed - Arrows indicate area that was cut
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14.b. You saved a bunch of cash
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14.c. Grab a cold one
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14.d. Enjoy the winter
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:wavey: Thanks for looking :biggthump
