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My 1997 E350 van blows only hot air; It seems as if the dash temperature control is not controlling the blend door. Is this a common thing? Is there something specific I should look for, or should I start disassembling the dash?
I replied to another person on this site regarding the same problem with a 1997 explorer. I had the same problem with a 1995 explorer. The air blend door was the problem, and in a web search I found that it may have been a faulty design of the door. I tried to contact Ford about it, but no reply, however I was told that although there has been no published admission of a problem, the design of the door has been changed from plastic to nylon.
If you stick your ear down by the black air plenum under your dash and adjust the temperature from one extreme to the other, you should be able to hear a clicking of the door trying to move. I actually heard mine start to creak before it got stuck altogether.
With the Explorers the whole dash has to come out to replace the entire plenum, since the blend door is incorporated into it as one big piece, and I emphasize "one big piece". It is about an $800+ experience at the dealer, but not much choice if you actually want to be able to stand being in your car. Good luck!!!
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