I have an Explorer with automatic A/C. The blend door actuator broke (a gear inside) so I replace it with a Dorman part (could not find the Ford ones anywhere). Part #604-202, looks identical and fits. But... doesn't work.
If I do the EATC test (OFF+FLOOR, then AUTOMATIC), the display shows error coded 024, 025, 052.
What is the meaning of those?

 

I don't have the manual in front of me but I'm pretty sure 24 and 25 are Blend Door Actuator codes. Did you remember to plug the wiring harness into the new actuator?
Yes, I've done that before on my Lincoln Mark VII. The whole inst. panel had to come back out.

Did you disconnect the battery while you were working on the system? If not, it may need to be reset.

 

The instructions that I had where saying that at the end of the cycle if I hit "DEFROST" it will clear the codes. Hmm...
LE: I did disconnect the battery and the code 024 appeared again. I am sure the others will creep up too.

 

Yes, exiting the self test by hitting Defrost will clear the codes.
Code 24 and 25 are Blend Door failure codes. According to the manual:
-Code 25 is a Hard Fault. No actual description given.
-Code 24 is a Runtime fault, Blend Door Failure.
The code 52 that you mentioned in your first post is a Runtime Fault:
-Solar Radiation (Sun Load) Sensor short to ground.

The shop manual then references corresponding Bxxx codes for electrical pinpoint test steps:
Codes 24 and 25: See code B1429.
Code 52: See code B1261.
You will need a DMM and the shop manual for these tests. Way too much info to type.

When you had it apart, were you able to move the blend door by hand?
Are you sure you reconnected the wiring to the actuator?

 

Thanks.
I took the final "wheel" from the old actuator and I was able to use it to rotate the blend door by hand with it.

I wonder if the Dorman actuator is not compatible?
The gears inside don't match the ones from the original Ford OE - that's what broke, just one small plastic gear.

 

The Dorman actuator is fine IF it's the right one. You may want to double check the part numbers to be sure.
Would be nice if you could disconnect the actuator from the blend door and see if it works that way. I usually try and figure a way to do that at some point during the repair.

 

I did disconnect the actuator from the door and did the test again.
The Ford one moves till I can hear the gears hitting that "bald" spot, and then stops. Throws codes 024, 025.
The Dorman one moves without visible problems, but at the end I have code 024.

 

If you move the temp control from Cold to Hot and back to cold, does the actuator change direction?
If you move the control to one extreme, does the actuator eventually "park".
Does the new actuator move when it's installed?

 

Ive never used an aftermarket actuator but be sure when they sold you one it was for EATC and not manual AC. Also if the door is broken it will allow the actuator to over extend and go past its normal operating range which will cause a code to set as well.

 

Thanks for the replies. Updates:
1. I have Automatic Temperature Controls (ETAC). I already returned the Dorman controller since I did found out that on their site was listed for "manual" A/C operation - didn't show that up in the parts store. The one that Dorman lists as "automatic" is 604-201 was not available on the parts store in my area, just online. I don't know if I should risk ordering it online.
2. I will try tommorow to ask the local Ford dealership if they have an OE one.

 

I did install today an actuator provided by Ford dealer. $44 and, after performing the reset, it works.

 

Great, glad you got it worked out.

 

I did forgot to say that I did found a crossreference table that explains why Dorman actuators didn't work with my 2001 EATC:
Table