I'm starting to pull apart the dashboard in my '94 3L to get access to the A/C Recirculate/Fresh air door. Either the actuator needs a replace or the recirculate/Fresh air door is off its hinge. I hear a rattle in the appropriate spot when I go over bumps, so I assume it's the latter.
I've got a thread for this procedure on an Explorer from the 'serious explorations' forum, but most of the pictures are busted. I've also got a Chilton manual that gives the order for pulling dash components. People in the Explorer forum said this happens all the time (i'm assuming similar components) and it's a pain to pull the dash, but it's a free fix.
Currently, I'm just pulling dash components in the order laid down in the Chilton manual and looking for equivalents to the parts listed in the forum. So far, I've removed the A-pillar covers, defroster cover, glove box, and lower steering wheel cover (plastic and metal). I can see an actuator and what I assume is the recirculate / fresh air door about two thirds to the left under the main dash, but it's buried. It looks like I'm going to have to pull the entire dash, but maybe only half out-- just enough to get to the thing. Next, I'm going to determine if what I see is what I think it is by flipping HVAC dials and seeing what moves. Any tips?

 

The recerc door is located in the engine bay, not in the Dash. What you usually see is the vacuum hose is pulled off or desinagrates from the vacuum actuator.


The Actuator is right next to the intake of the engine on the passenger side. (Or directly opposite of the blower motor.


If it is the door, it looks like you have to unbolt the housing in the engine bay from the firewall, but from what I am reading it is non-serviceable.

 

Huh, crap. Glad I asked.
You don't have a picture you could put an arrow on, do you?

 

If you look to the right of the air box, you see a silver cylindrical valve, that actuates your air inlet. In the pic it is in the center just above the alternator/oil fill tube.

 

$5 fix. You're my hero.

 

Your Welcome!