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Explorer, Sport Trac, Mountaineer & Aviator 1991-1994, 1995-2001, 2002-2005, 2006-2010 Ford Explorer

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  #1  
Old 01-02-2012, 11:39 AM
judsy judsy is offline
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Please help--05 explorer blend door

Sorry to beat a dead horse here but,
I've read alot of the threads on this problem and the link that is stickied is broke. I took out the actuator motor and it still works.I saw the heater cheater or whatever its called but I guess my question is what part of the door breaks and is there way to open it manually by say drilling a hole where the stub goes in to open it.
The dealer told $1400 for labor and $400 for the part and I already have it to the point of taking out the act motor.
Oh and its a manual system.
Thanks for any responses
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  #2  
Old 01-02-2012, 06:05 PM
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photos at bottom of this page might get you going in the right direction. I guess you can pin the door in the middle and then control blower speed for more heat. Probably have to move it back next summer.

How To: Replace Blend Door Actuator in 3rd Gen Ex. - Ford Explorer Ranger Enthusiasts "Serious Explorations"®
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2002 SuperCrew 4 x 4 5.4 XLT -115K miles -NEW
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  #3  
Old 01-03-2012, 07:14 AM
judsy judsy is offline
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Quote:
Originally Posted by steve(ill) View Post
photos at bottom of this page might get you going in the right direction. I guess you can pin the door in the middle and then control blower speed for more heat. Probably have to move it back next summer.

How To: Replace Blend Door Actuator in 3rd Gen Ex. - Ford Explorer Ranger Enthusiasts "Serious Explorations"®

I used this thread to get the actuator out ( Thank You Rondo),
But I"m not sure which pics you mean.
Thanks again
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  #4  
Old 01-03-2012, 10:00 PM
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well i have not worked on a 2002-2005 blend door, but if you have the actuator off i think your close. I would think you could take a wooden dowel and shape it like the shaft , put it into the door, and rotate and clamp. I have also heard of guys drilling a 1/8 inch hole in the duct and poking a welding rod or coat hanger thru the hole and pushing the door to one end and tape the rod in position... just some ideas.
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  #5  
Old 01-18-2012, 02:59 AM
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Quote:
Originally Posted by judsy View Post
I used this thread to get the actuator out ( Thank You Rondo)
You are welcome!!

The shaft will still turn. The problem is with a damaged gear. This is mine with 3 teeth broken off:

Click the image to open in full size.
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Old 01-18-2012, 07:27 AM
judsy judsy is offline
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Quote:
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You are welcome!!

The shaft will still turn. The problem is with a damaged gear. This is mine with 3 teeth broken off:

Click the image to open in full size.
This is great news. I didnt try to fix it yet because taking out the dash is a scary thing for me and I didnt want to spend $89 on the actuator if i wasnt sure it was shot, and giving the ford garage $1500 to $2000 is out of the question
Since I"m laid off for the winter.
I"ll give it a try, thanks again Big Rondo...Your a big help
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  #7  
Old 01-18-2012, 07:37 AM
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Quote:
Originally Posted by judsy View Post
This is great news. I didnt try to fix it yet because taking out the dash is a scary thing for me and I didnt want to spend $89 on the actuator if i wasnt sure it was shot, and giving the ford garage $1500 to $2000 is out of the question
Since I"m laid off for the winter.
I"ll give it a try, thanks again Big Rondo...Your a big help
No problem. If you go by my write-up you wont have to take out the dash, just the console. It is a step by step with pictures of every step. Hey if I can do it anyone can!!
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Old 03-25-2012, 02:32 PM
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BUMP for an update!
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Old 04-05-2012, 03:08 PM
taxgod4u taxgod4u is offline
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is there any simlar easy fixes for the fresh air/recirc actuator in the climate controled 2003's Mine tends to stop working when following a tar truck...
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  #10  
Old 04-05-2012, 03:38 PM
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Quote:
Originally Posted by taxgod4u View Post
is there any simlar easy fixes for the fresh air/recirc actuator in the climate controled 2003's Mine tends to stop working when following a tar truck...
Dont follow tar trucks.... Simple enough.... Philip
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Old 04-06-2012, 11:15 AM
taxgod4u taxgod4u is offline
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aquanut
that sure was helpfull. eh
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  #12  
Old 04-06-2012, 04:27 PM
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aquanut
that sure was helpfull. eh
I was responding to the "easy fixes" request..... Philip
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  #13  
Old 04-07-2012, 09:15 AM
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on the fresh air door, the arm failes. That happened to mine. Easy fix is to remove the glove box door and inside walls for access. You will see a plastic grate with 1/2 inch square holes in it. Look inside and you will see the broken arm. Easy fix is to take a dowel and push thru the grate and push the door closed. I put a VEE notch on the dowl so i could clamp it on the plastic grate. MIne failed in winter and very cold on passenger side. That was 2 years ago, still "fixed".
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2010 EDGE FWD - V6 ----------40,000 miles
2002 Explorer 4 x 4 4.0 XLT --- 162,000 miles
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Old 05-07-2012, 04:29 PM
jrfromsocal jrfromsocal is offline
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Hi BigRondo:

Could you direct me to your write-up on how to fix the Fresh / Recirc door without having to take out the dash?

I would greatly appreciate it.
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  #15  
Old 06-29-2012, 10:48 AM
Pottsie_Honda Pottsie_Honda is offline
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For anybody having this issue, there is an easy way without using any rods or sticks. Turn your heat on and you will probably hear a clicking, open the glove box and release the stop tabs so that you can get access to the back of the climate control panel. There is a lever (use the intensity of the clicking to help you find it. I have huge hands so I usually have my brother reach it.) and flip it. That's for my '02 Exploder, but I'd bet almost all are similar.

Where I live we have cold winters so I only have to do this once a year. If you constantly switch back and forth from cold and hot this might be an inconvenience.
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Old 06-29-2012, 10:48 AM
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