I have a 2002 Ford Explorer XLT 4x4 with the manual (aka: ****) climate control system. I only get air flow from the dash (panel) vents, no significant air to the windshield defrost or the floor when set to the appropriate positions. With the vacuum manifold removed from the back of the selector switch, I can pull and maintain a vacuum on all the vacuum motors (blue, white, red, yellow vac. lines) and I can hear each one move when the vacuum pump is removed. With the engine running I have about 16 in-Hg from the black vacuum source line. I saw on another post that the system is design to "fail safe" to the defrost position if vacuum is lost. Shouldn’t I get only defrost air with the engine running and the heater/defrost turned on but the manifold unhooked (i.e., no vacuum)? As it is, I still only get air flow from the panel/dash vents.

 

When you pull a vacuum on the various motors, one at a time, do any cause a change in the air flow path?

-Rod

 

When I apply vacuum to each there is no change in air flow but they each hold a vacuum.

 

where is the vacuum motor and door for the defrost and how do you get to it?
-Bryan

 

The defrost vacuum motor is on the driver's side of the center stack, kind of left of the bottom edge of the radio as you're sitting in the driver's seat. The service describes removing the center instrument cluster and plenum chamber to get to the motor. Doesn't look like a trivial task.

If you want PDF files from the service manual for accessing, send me a Private Message with the request and include an e-mail address for you.

-Rod

 

click on this link... about the 4th post down shows a diagram of how things work.. The vacuum cylinders that move the doors are spring loaded. When you remove vacuum, YES the doors go to a position so all air goes to the defrost.

https://www.ford-trucks.com/forums/9...-please-2.html

 

look at cylinder #1, door #2 in the above drawing... yours is broke or stuck = no defrost.

 

Do you still have the PDF Files and can you send them to me.
Thanks
Craig
craigbudzinski@gmail.com

 

Files sent.

-Rod