JFrank, Can you email this to Ken (webmaster)and have him post it under the Tech Articles. Many people will freeze to death this winter if you don't!!!!

 

Please send me the instructions as well, chuck.cole@***.net. Thanks.

 

send it, man! Thank you very much.

jperlette@oakhall.org

 

If you get the chance can you please send me the "Fix" file.
Our 99 XLT has started to have problems with the Blend, and
the local Ford dealer is telling us between $800 - $1,000 to
get it fixed.

Thanks and have a Very Merry Christmas.

 

Has anyone got this fix yet?????

I have been waiting for a while now............

 

While I don't have the blend door problem YET, I would appreciate the instructions for future reference. Please email them to me at:

mroettger1@comcast.net

thanks,
Mike

 

Would you please be so kind as to send it to me as well. I just looked at a 97 ex tonight and will probably buy it tomorrow. Just want to be in the loop if it ever happens to me, or at least make it break while it is still under the 30 day warranty. hoppywsurf(No Email Addresses In Posts!)

Thanks,

Hoppy...

 

Yes, please send to me as well, need heat.

rjardine(No Email Addresses In Posts!)

 

me too please. rjardine(No Email Addresses In Posts!)

 

>Yes!, I have a complete fix for this. Leave your email and
>I'll send you instructions on what to do.

We'd appreciate a copy of that, too. Please send it to:

gkalpin@vanbortelford.com

Thanks!

 

Can I have the instructions as well please

T
'98 XLT

zoti(No Email Addresses In Posts!)

 

[updated:LAST EDITED ON 19-Dec-02 AT 12:07 PM (EST)]>Yes please please send me the info...
>help me with my 97 Sport..
>r1grrl(No Email Addresses In Posts!)
>
> Thank you!


I too have a broken heater blend door in my '96 Explorer. In my case it was all hot air, but depending on where the door is when it breaks it could be all cold air. The dealer said there was no recall program and said it would be $700 to $800 labor to pull the center console and dash, plus $110 for a new heater plenum. I decided to try to fix it myself by cutting out the bottom of the plenum with a Dremel and dropping the heater blend door out. It is not elegant, but it is a free repair that works fine.

Before you start, go to the Parts Department and look at a new plenum assembly. You will be able to see the operation of the blend door within the plenum and where you can safely cut the hole. Note where the core is and make sure to stay away from it. The core is like a miniature radiator, and it juts down vertically at an angle. Your cut will be between the core and the firewall. It is roughly a 3 inch triangular patch with the ½ inch round shaft on the driver side. I ground off the base of the shaft. It has a "star" on the bottom. Start your cut on one side of the shaft hole; go all the way around the triangle, ending on the other side of the shaft. Take your cut right up to the base of the shaft hole and you can wiggle the blend door out. When mine came out, so did the broken top one inch of the shaft. Save the pieces.

In my case the blend door shaft was split in two. I used J-B Weld epoxy to glue it back together. For added strength, I drilled small holes where the blend door flap attaches to the column and made three steel wire wraps around the top of the shaft. Leave the top 3/8 inch of the shaft clear. It fits into the top of the plenum. Tuck the twisted end of the wire into the foam.

Rotate the temperature control **** to make sure the blend door is mated to the acutor. Note that the motor actually tries to drive the blend door too far. The temperature control **** only needs to be set about ¾ of hot or ¾ cold and the blend door is closed. Any further motion beyond that just over-torques the blend door and is the cause of premature failure. I put a little mark on my temperature control indicator where to stop.

Finally, carefully glue the triangular patch back on plenum. Make sure the shaft is free to rotate. Put a cap over the bottom end, where you ground off the bottom of the shaft, to keep the shaft properly positioned.

Given all the people with this problem, I cannot believe Ford will not recall the unit. In my opinion, it is safety issue not to have heat control.

John V
Beaverton, Oregon

 

Yes, please send me the fix for the blend door. I have a 1997 Explorer, XLT, I removed the actuator and saw that it rotated as I turned the temperature. I then felt for he blend door on the top of the plenum, and it appears to have dropped into the plenum (most likely cracked or or broken). I now get lots of heat (which is open for the winter) but I know I've got to fix this problem soon. My email address is erose1422(No Email Addresses In Posts!). Thanks.

Also, anyone who has performed this fix I'd appreciate your experiences. Thanks.

 

GREAT !!

Send me a copy Please.............THANKS Doug

DEZRACER at earthlink.net

:-X12

 

Send it to me too. Sounds like a problem I'm having on my 92. Maybe it's the same problem?
jbozzelle(No Email Addresses In Posts!)
John Bozzelle