How to: - Replace Front Blend Door Actuator in 3rd Gen Ex. | Page 18 | Ford Explorer Forums

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

Prefix for threads which are instructional.
Hello eveyone. I am having a heat issue as well, but I am not sure it is the blend door as described in this thread.

My heat seems to work fine. No clicking or clunking. Airflow seems to change to the appropriate vents when I select them and it is strong and hot.


My problem is my feet are always freezing. It feels as if there is hole in my firewall and cold air is coming is when I drive down the highway at high speeds. As stated above, everything works fine and I can feel the heat blowing hot out of the floor vents, but there is definately something making my feet cold.

Any ideas? I can't actually feel "cold air" coming from anywhere, but my toes freeze whenever the weather is extremely cold???

Sorry about the late reply. It sounds like you have the re-circulation door issue. If you do a search, there are many threads about it.
 



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Thank you very much for the instructions on the blend door replacement. The instructions are very thorough and easy to follow. I was able to replace the part in ~3hrs. I didn't have to cut the dash, either. Thanks again and Nice job!!

Welcome aboard!! :salute:

Nice job on the fix. Glad I could help out! :biggthump
 






Blend Door

I forgot to say i did this everything as bigrondo said except the cutting of the dash. He mentioned that you might be able to without cutting out the dash and he was right. Just had to loosen a few extra screws and pull a bit.. Thanks again for saving me money. Ed Adkins
 






I forgot to say i did this everything as bigrondo said except the cutting of the dash. He mentioned that you might be able to without cutting out the dash and he was right. Just had to loosen a few extra screws and pull a bit.. Thanks again for saving me money. Ed Adkins

Welcome aboard!! :salute:

You're welcome. Glad I could help out! :D:thumbsup:
 






This is what is great about the internet. I had to join the forum just to say thanks. I was fretting about taking it in to the shop. Did it yesterday, laptop by my side....no problems, no dash cutting. All is well... thanks again!
 






This is what is great about the internet. I had to join the forum just to say thanks. I was fretting about taking it in to the shop. Did it yesterday, laptop by my side....no problems, no dash cutting. All is well... thanks again!

No problem!! :eek::thumbsup:
 






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.

Click here: Groaning sound made when temperature changed - opening and closing twice

This past 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?

This tutorial is 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.
 






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.

Click here: Groaning sound made when temperature changed - opening and closing twice

This past 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?

This tutorial is 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.

I am not familiar with the dual zone climate control. I will check my shop manuals tonight when I get home and see what I can find in regards to your issues.
 






Just wanted to thank you for the excellent write up! I got it done in about an hour and a half thanks to you!
 






Just wanted to thank you for the excellent write up! I got it done in about an hour and a half thanks to you!

Glad I could help!
 






Great write-up! I just replaced it today and the guide worked perfectly. NO MORE CLICKING/KNOCKING/BANGING sounds lol! I used the Dorman 604-209 part. It was about $35 on Amazon. Took me about 3 hours start to finish. Some of that time was going to the auto store to get an 8mm wrench (definitely can't fit a rachet + socket to remove the bottom front screw!). I didn't have to cut that much of the dash. Other than that kudos bro!
 






Great write up :thumbsup:.

Feel free to do the rear actuator now. Mine is stuck on cold so you've got a couple months as we're just entering summer :D
 






Great write-up! I just replaced it today and the guide worked perfectly. NO MORE CLICKING/KNOCKING/BANGING sounds lol! I used the Dorman 604-209 part. It was about $35 on Amazon. Took me about 3 hours start to finish. Some of that time was going to the auto store to get an 8mm wrench (definitely can't fit a rachet + socket to remove the bottom front screw!). I didn't have to cut that much of the dash. Other than that kudos bro!

Thanks! Just trying to give a little back to the community. :D:thumbsup:
 












Thanks! I'll get at it one of these days.
 












Just wanted to give a HUGE thanks for this write-up! It was well written and I just finished using it about 10 mins ago to change the actuator out on my wifes Explorer! :)

I ordered this part right here and it worked perfectly:
http://www.amazon.com/gp/product/B0037Z3A48/ref=oh_details_o00_s00_i00

It only took roughly 1-1.5 hrs and that includes running back and forth inside the house to cool off from the heat and get tools.

Not that we will be using the heat any time soon, but we've definitely needed the defrost a few times recently!
 






Just wanted to give a HUGE thanks for this write-up! It was well written and I just finished using it about 10 mins ago to change the actuator out on my wifes Explorer! :)

I ordered this part right here and it worked perfectly:
http://www.amazon.com/gp/product/B0037Z3A48/ref=oh_details_o00_s00_i00

It only took roughly 1-1.5 hrs and that includes running back and forth inside the house to cool off from the heat and get tools.

Not that we will be using the heat any time soon, but we've definitely needed the defrost a few times recently!

Nicely done. Glad I could help out! ;)
 






Well done.

Hey BigRondo

Just wanted to give you a big thanks.
I followed your procedure on my 2004 Explorer XLT .
Took about 3 hours and went smooth as silk.
I owe it all to your excellent pictures and discriptive process.
Thank you again for the help.

Steve
 



Join the Elite Explorers for $20 each year or try it out for $5 a month.

Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





Hey BigRondo

Just wanted to give you a big thanks.
I followed your procedure on my 2004 Explorer XLT .
Took about 3 hours and went smooth as silk.
I owe it all to your excellent pictures and discriptive process.
Thank you again for the help.

Steve

Welcome aboard Steve!! :salute:

Glad to help out one of our neighbors from the great white north!! ;):thumbsup:
 






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