Expedition & Navigator1997 - 2002 and 2003 - 2006 Ford Expedition and Lincoln Navigator
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Anybody try this method of cutting through the plenum box behind the glove box and using an off the shelf door. I am in the middle of this but can not get the new one in, anyone have a trick? I can see why the hetertreater guy has a 2 piece unit.
Yes I did watch the heatertreater videos but no clues on installing a one piece door. I'm at the point where I may just pull the dash but am looking for someone who has successfuly tried what I am doing without buying the two piece door for $120+shipping.
There is a post here somewhere that shows how to repair the blend door by drilling through the shaft and using a small piece of a drill or nail to secure/pin the parts together. I saw this a couple of months ago.
I have done it with a one piece blend door (dorman). I feel your frustration. It takes a lot of twisting and bending to get it to go in. I ended up taking a dremel to it and shaved just enough off it for it to pop in. Good luck
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