i tried to fix my blend door for my heater but i did not suceed i think the door itself is broken. has anybody ever done it. how much does bthe part cost. anyone know how much it would cost at the dealer. in canadian dollars

 

I've been to lazy to fix mine. I just cut a hole in the heater box and moved the door by hand. So, I got a summer and winter position. For over a year I've adapted to it just fine.

 

where did you cut?

 

This has been discussed before but I was never able to find the exact information needed for a quick temporary fix for my 97. I wanted to find the best point of entry to physically move the blend door. So consequently, I had to turn my plenum box into Swiss cheese. The black plastic plenum box is located directly behind the glove box door. The glove box is held in by a plastic tab on each side. Pressing these in will allow the box to swing down. Removal is not necessary. The plenum box has a vertical and horizontal seam. The heater core is located to the right of the vertical seam. Do not drill any holes to the right of the seam. Easiest entry is to the left of this seam and above the horizontal seam. This space is deep and the only thing you have to worry about is cutting into the external control hoses. It is possible to cut away enough plastic to get your hand in. I drilled some large holes and cut away the rest with a razor knife. You have to reach in about six inches and then bend your hand to the right behind the heater core to get to the blend door. Mine was stuck in the AC position even though the rotary control was set to max heat. The door wouldn't budge when I grabbed it. So, I set the temperature control to cold. After I heard the actuator motor stop, I grabbed the door and then set the temperature back to the high heat position. As the motor turned, I was able to move the blend door to the heat position. The door seems to want to stay where you put it using this method. Used a small 5/8 inch hose taped to a shop vac to reach through the opening and suck up the plastic chips. I sealed up the hole that was made in the case with aluminum (actual metal) furnace tape that is very strong and has glue that gets even better with heating. Temperature regulation is now a function of the OFF, fan speed control, and window opening, about the same as in my old F110 pickup. This might help you get through a tough spot and since you get a new plenum box when the final repair modification is done, you don't have to worry about the hole.