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

 

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

 

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.

 

You are welcome!!

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

 

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!!

 

BUMP for an update!

 

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

 

aquanut
that sure was helpfull. eh

 

I was responding to the "easy fixes" request..... Philip

 

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".

 

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.

 

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.