How to: Replace Front Blend Door Actuator in 3rd Gen Ex.

[jaked418]

Sounds like you saved some cash! I'm glad the write-up helped!!!!
Posted via Mobile Device

Yes...Mucho Money Saved!

 

[BigRondo]

Yes...Mucho Money Saved!

Good deal! :biggthump

 

[jakedrew]

why isnt this a sticky? It dont matter really to me personally as I fixed mine here thanks to the older write up.

I know I shouldnt get worked up over it, but the guy took the time to document this common problem and the least the site administrators can do is a sticky.

I mean there is a sticky for a wiring harness /rubbing wires that isnt common at all. More people have the blend door go out .

 

[RUSHXYZ]

I took apart actuator and was able to shorten the small gear buy shaving a bit of the top then i added some small washers below it to raise it to catch the spindle on the motor it is working we will see for how long.

 

[BigRondo]

why isnt this a sticky? It dont matter really to me personally as I fixed mine here thanks to the older write up.

I know I shouldnt get worked up over it, but the guy took the time to document this common problem and the least the site administrators can do is a sticky.

I mean there is a sticky for a wiring harness /rubbing wires that isnt common at all. More people have the blend door go out .

I agree!!

 

[BigRondo]

I took apart actuator and was able to shorten the small gear buy shaving a bit of the top then i added some small washers below it to raise it to catch the spindle on the motor it is working we will see for how long.

Welcome to the forum.


Good innovation with the BDA repair!!

 

[BrooklynBay]

Thanks for taking the time to make this how to thread on replacing the blend door actuator! It's now a sticky on the top of this section.

 

[bumpncarstereo]

Great how too, thanks Big Rondo.

Has anyone ever had an issue with the blend door it self? My wife's 03 explorer is making a weird noise, well actually 2 different noises depending on what the position of the hvac controls. I made a video and put it on you tube so you can see what i am talking about. is that just the actuator, or maybe the blend door as well?

also i am looking for the part number, is there 2 different parts, maybe one for the auto temperature control, and one for the manual?

you tube video link

 

[my1zamboni]

Big Rondo congrats on getting the sticky. You deserved it. This is one amazing write up, Thank you again for taking the time to do this.

 

[BigRondo]

Thanks for taking the time to make this how to thread on replacing the blend door actuator! It's now a sticky on the top of this section.

You're welcome & thanks for the sticky!! :

Big Rondo congrats on getting the sticky. You deserved it. This is one amazing write up, Thank you again for taking the time to do this.

No problem. Glad I could help out!

 

[BigRondo]

Great how too, thanks Big Rondo.

Has anyone ever had an issue with the blend door it self? My wife's 03 explorer is making a weird noise, well actually 2 different noises depending on what the position of the hvac controls. I made a video and put it on you tube so you can see what i am talking about. is that just the actuator, or maybe the blend door as well?

also i am looking for the part number, is there 2 different parts, maybe one for the auto temperature control, and one for the manual?

you tube video link

bumpncarstereo, I checked out the video and it sounds like the actuator to me. But it's really hard to tell with the background noise. I know mine would click when I changed it from cold to hot and with the fan on high it would eventually blow the blend door closed. Then it stopped blowing closed and just clicked.

As far as the part # goes, I highly recommend getting the actuator at a Ford dealer so you get a genuine Ford part. Others have had issues with the aftermarket actuator (autozone, advanced auto, etc.). I got mine at my local Ford dealer for $69.53 + tax. You can also order it cheaper online @ www.silverstatefordparts.com or www.tousleyford.com or www.rockauto.com, they are a vendor on our forum and offer a discount for forum members.

When you order the actuator, just be sure to give who ever you order it from your VIN and they will make sure you get the right part.

There are many threads about the blend door itself. You should be able to find them by searching.

Good luck and keep us posted!!

 

[bumpncarstereo]

i was thinking of getting from rock auto, but if people have an issue with aftermarket i guess i will pass on that. i am just not usually near a ford dealerships. but as some may understand the wife wants heat asap, being that we are coming up fast on another western ny winter.

 

[BigRondo]

i was thinking of getting from rock auto, but if people have an issue with aftermarket i guess i will pass on that. i am just not usually near a ford dealerships. but as some may understand the wife wants heat asap, being that we are coming up fast on another western ny winter.

Check Rock Auto first. I believe they have the Motorcraft part!!

 

[Yasla]

I used your post with great success, just got it done. A few updates that are possible, I did use ratcheting box wrench, got all three screws out in about 3 minutes, was really no problem (5/16"). Putting back in was easy for bottom two screws, I placed some chewing gum in a socket and got the upper screw started, then used ratchet wrench to tighten down. Maybe 10 minutes for all three. Also, I didnt need to cut dash at all, could get part out and new one in intact, just need to wiggle the shaft out carefully, then it slides out the back. I was very happy to not cut dash. Side note, I bought the replacement Dorman part 604209 at Rockauto, was a perfect match for $40. First one I bought at Autozone was a Dorman 604202? but wrong part number, had a D-shaped pin. So I am back up and running on this issue, very happy to save the $$. Thanks!

 

[BigRondo]

I used your post with great success, just got it done. A few updates that are possible, I did use ratcheting box wrench, got all three screws out in about 3 minutes, was really no problem (5/16"). Putting back in was easy for bottom two screws, I placed some chewing gum in a socket and got the upper screw started, then used ratchet wrench to tighten down. Maybe 10 minutes for all three. Also, I didnt need to cut dash at all, could get part out and new one in intact, just need to wiggle the shaft out carefully, then it slides out the back. I was very happy to not cut dash. Side note, I bought the replacement Dorman part 604209 at Rockauto, was a perfect match for $40. First one I bought at Autozone was a Dorman 604202? but wrong part number, had a D-shaped pin. So I am back up and running on this issue, very happy to save the $$. Thanks!

Glad I could help out! Saving cash is not a bad thing!!

 

[Scootman]

Big Rondo.....you 'da man

I just finished your procedure and got my blend door all fixed. I bought the wrong one so I moved the gears and motor over to the old gear box. Got it aligned properly (output shaft), greased 'er up and it is rock solid.

Thanks so much for putting this info up, could not have done it without your process. I live in Silicon Valley so I assume it would have cost me closer to a grand to get done. Told my wife I need a kick back or something for saving so much......maybe a set of HC pistons for my Roadstar Warrior......lmao

GOOD ON YA........!!!!!!

 

[BigRondo]

Big Rondo.....you 'da man

I just finished your procedure and got my blend door all fixed. I bought the wrong one so I moved the gears and motor over to the old gear box. Got it aligned properly (output shaft), greased 'er up and it is rock solid.

Thanks so much for putting this info up, could not have done it without your process. I live in Silicon Valley so I assume it would have cost me closer to a grand to get done. Told my wife I need a kick back or something for saving so much......maybe a set of HC pistons for my Roadstar Warrior......lmao

GOOD ON YA........!!!!!!

Get something nice for yourself!! : Glad I could help out. Enjoy the heat! :fire:

 

[inhinyero_ako]

Hi Big Rondo!

Thanks for your post. It helped me alot and saved me money.

Took me abt 4hrs to do mine. I did not cut anything though. I had to use magnets
to hold the screws.

Thanks again.
rich

 

[BigRondo]

Hi Big Rondo!

Thanks for your post. It helped me alot and saved me money.

Took me abt 4hrs to do mine. I did not cut anything though. I had to use magnets
to hold the screws.

Thanks again.
rich

You're welcome. I'm glad I could be of assistance. Keep on 'truckin

 

[acej62]

very good instructions and pictures!

I would like to thank you for this instruction!
This is the best instruction and set of pictures I have ever used!
It took about 4.5 hrs to complete the job.
I contacted my local dealer and they said it would be over $1000 to repair this problem.
I appreciate this forum and input on common issues from my fellow ford owners!
Thanks again, and keep up the good work!