Anybody install one of these? Doesn't look too difficult. Looks like maybe an hour instead of a day. BTW my f150 is an early 97.

 

I put one in my 1997 a couple of years ago.
No big deal, never had any more problems with AC/heater system.
There is a couple of good videos on Youtube that show where to cut. I used a Dremel with a diamond cutting wheel on slow speed.
Use good quality HVAC installer tape to seal it and it should last a long time.

 

Installed the blend door kit and replaced the actuator at the same time. Turns out the door doesn't close all the way. It lacks about 1/2". Could it be the potentiometer has gone bad? How can I test the resistance of it? what values should I see? Thanks

 

Some say that if you disconnect the battery for a few minutes then reconnect it, the HVAC module recalibrates the actuators when booting up.

 

I disconnected the battery for about 10 minutes and tried again. May have helped a little. Instead of being able to easily put my index finger in the gap, Now my pinky finger fits. Any hints on how to check the resistance of the potentiometer?

 

I don't recall if listing URLs to other Ford forums is allowed, but if you Google "test ford temp ****", the second link will take you to another Ford forum that lists measuring the resistance using a voltmeter and the pins to connect to.