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

[BigRondo]

So glad to have found this, 'cause I'm gonna have to be doing this before long. Thanks for taking the time to share all this info!

You're welcome. Good luck getting it sorted.

 

[vtmcgyver]

Thought I'd add some information to this sticky post. Here is an excerpt from a 2002 Ford Service manual showing the Vacuum diagram and door positions for the 2002-2005 Explorers.

http://www30.zippyshare.com/v/34866492/file.html

 

[da2962]

Add my thanks to Big Rondo and all who posted to this fix

Just wanted to add my gratitude for this sticky. Just finished the job a few minutes ago. Was a lot more maneuvering than I originally expected but it was worth it. Paid $90 for the part from the dealer, and about 2 hours work and its fixed. Like others I was able to avoid cutting, but I could see where it would have made it a little easier. I also removed the bezel around the radio and heater/AC controls to give me a better view and I think it was worth the few seconds it took to remove it. Only other thing is I would more than highly recommend the ratcheting box end wrench (8mm) I would say its a requirement to cut down on the swearing.

Again a big THANKS to Big Rondo for taking the time and extra effort to make this so much easier for the rest of us.

 

[BigRondo]

Just wanted to add my gratitude for this sticky. Just finished the job a few minutes ago. Was a lot more maneuvering than I originally expected but it was worth it. Paid $90 for the part from the dealer, and about 2 hours work and its fixed. Like others I was able to avoid cutting, but I could see where it would have made it a little easier. I also removed the bezel around the radio and heater/AC controls to give me a better view and I think it was worth the few seconds it took to remove it. Only other thing is I would more than highly recommend the ratcheting box end wrench (8mm) I would say its a requirement to cut down on the swearing.

Again a big THANKS to Big Rondo for taking the time and extra effort to make this so much easier for the rest of us.

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

 

[c0rtney]

Just finished this job. I had been putting it off for years, it looked like it was going to be a big headache but it was actually a pretty easy job. Wish I would have done it sooner. I avoided cutting the dash as well, thank you sooo much for this awesome write up big rondo!!!

 

[Gideon01]

thanks a ton for the step by step, i just finished the job.
it took less then 2 hours, and just about 2 six packs to finish.
the clickings been driving my wife nuts since april, but she just recently started to wine about it due to not having heat in the mornings so i figured id better fix it.

my local ford dealer wanted 89.00 for the part. i found it at autozone for 46.00, i also found it at www.#########.com for 32.00 but i wanted it fixed today not next week when the part arived in the mail.
the same dealer that wanted to rob me on the part quoted me for 4.5 hours of labor it would take to fix it for me..

i did cut the dash, before i took the panel off that covers the one you cut i marked it so i knew how far not to go so nobody would see the cut. i also used my dremel instead of a utility knife the cut was clean and quick.

 

[BigRondo]

Just finished this job. I had been putting it off for years, it looked like it was going to be a big headache but it was actually a pretty easy job. Wish I would have done it sooner. I avoided cutting the dash as well, thank you sooo much for this awesome write up big rondo!!!

You're welcome. My way of giving back to the community.

 

[BigRondo]

thanks a ton for the step by step, i just finished the job.
it took less then 2 hours, and just about 2 six packs to finish.
the clickings been driving my wife nuts since april, but she just recently started to wine about it due to not having heat in the mornings so i figured id better fix it.

my local ford dealer wanted 89.00 for the part. i found it at autozone for 46.00, i also found it at www.#########.com for 32.00 but i wanted it fixed today not next week when the part arived in the mail.
the same dealer that wanted to rob me on the part quoted me for 4.5 hours of labor it would take to fix it for me..

i did cut the dash, before i took the panel off that covers the one you cut i marked it so i knew how far not to go so nobody would see the cut. i also used my dremel instead of a utility knife the cut was clean and quick.

You're welcome. Nicely done.

 

[justanother1]

Thanks for the very detailed instructions. After reading these, I was thinking this was going to be much harder than it was. Did this in 2.5 hours (including running across town to the dealer for the part). I had no need to cut the dash.

 

[BigRondo]

Thanks for the very detailed instructions. After reading these, I was thinking this was going to be much harder than it was. Did this in 2.5 hours (including running across town to the dealer for the part). I had no need to cut the dash.

You're welcome!! Glad to help out

 

[sabasigh]

let me add my Thanks here as well. I went to tackle this today but unfortunately all the pics were gone. anyway print out the instructions and about 2.5 hours later I have heat again.

 

[BigRondo]

let me add my Thanks here as well. I went to tackle this today but unfortunately all the pics were gone. anyway print out the instructions and about 2.5 hours later I have heat again.

Yeah, sorry about the missing pics. Photobucket says I am using too much bandwidth, so until I get a paid account with them the pics won't show.

Nice job getting it sorted.

 

[JackSpackle]

Many Thanks

Big Rondo

First, foremost and always, thank you for serving your country and your community!!!!!

Your fix was sooo easy and great detail. No cutting necessary. If I didn't have to stop and get the part, I would have probably completed this in 1.5 hours.

Thank you again.

Jack

 

[BigRondo]

Big Rondo

First, foremost and always, thank you for serving your country and your community!!!!!

Your fix was sooo easy and great detail. No cutting necessary. If I didn't have to stop and get the part, I would have probably completed this in 1.5 hours.

Thank you again.

Jack

Thank you

Nice job getting it sorted.

 

[Prdude79]

I followed this tutorial and fixed the heat. Thanks so much for the details. Luckily I didn't have to cut my dash board to take out the actuator.

 

[BigRondo]

I followed this tutorial and fixed the heat. Thanks so much for the details. Luckily I didn't have to cut my dash board to take out the actuator.

Glad I could help out. Nice job getting it fixed.

 

[BigRondo]

I guess the bandwidth issue with Photobucket is over for now and the pics are back up.

Enjoy!

 

[rajron]

Thank You for the info/procedure it was right on making the task relatively easy. The original actuator was held in with only three screws making it easier to remove, it worked for ten years, so i put the new actuator in with only three screws.

 

[BigRondo]

Thank You for the info/procedure it was right on making the task relatively easy. The original actuator was held in with only three screws making it easier to remove, it worked for ten years, so i put the new actuator in with only three screws.

Glad i could help out!!

 

[BigRondo]

Well after 3 years the Motorcraft replacement actuator failed. I had no telltale clicking this time. Once I got it out I discovered that it moved in only one direction, COLD.

Due to lack of funds & the fact that Old Man Winter will be bearing down on us soon, this time I went with the Doorman part: 604-209. I ordered it from Advance Auto online and picked it up at the store. This way I could use the Promotion Code P20 and save 20%. Got it for under $48. The dealer price was $92.xx before tax.

I just discovered a 30% code for Advance Auto: TRT30, damn!! I'll have to use that for the rear actuator. I'll be doing that one next.

I will keep you guys posted on how well the Doorman actuators perform & last.