I have a 2002 Explorer with the rear A/C option. I have the clicking sound described in the TSB below coming from the blend door in the rear.

Has anyone else had this problem and fixed it themselves? I’d like to know how you did it.

My truck is out of warranty unfortunately.

Thanks -Brad

Technical Service Bulletins Summary

Make: FORD
Model: EXPLORER
Year: 2002
Service Bulletin Number: 01126
NHTSA Item Number: 622673
Summary Description:
SOME VEHICLES EQUIPPED WITH THE MANUAL A/C SYSTEM MAY EXHIBIT A CONTINUOUS CLICKING NOISE FROM THE BLEND DOOR ACTUATOR WHENTHE BLOWER SPEED IS SET AT THE #2 POSITION AND THE TEMPERATURE CONTROL **** IS SET BETWEEN THE 12:00 AND 2:00 POSITION. *TT

 

Anyone have a suggestion?

 

Stop by your friendly, neighborhhod Ford dealer & ask them to show you that TSB which will have instructions on how to fix tis. Or join www.alldata.com for only 25 bucks & you can pull the TSB up in your computer.

 

Well according to what you posted it is a service message and not a TSB.

Here are the steps to replace the bad controller. Just be carefull not to break the trim panels and make sure you have all the appropriate tools to do the job.

Removal and Installation

Remove the LH quarter trim panel. For additional information, refer to Section 501-05.
Disconnect the wiring harness.
Disconnect the electrical connectors.
Detach the electrical connector pin-type retainer.

Disconnect the vertical air duct from the auxiliary climate control housing.

Remove the bolt.

Remove the bolt.

Remove the nut and position the auxiliary climate control housing away from the quarter panel.

Remove the temperature blend door actuator.
Disconnect the electrical connector.
Remove the screws.
Remove the temperature blend door actuator.

To install, reverse the removal procedure.

 

I have a 2002 Explorer that is experiencing this problem. I purchased the replacement Actuator. Can you please send me the instructions to Remove the Interior Panel. You reference it in your original note as Section 501-05

> Remove the LH quarter trim panel. For additional information, refer to Section 501-05



Thanks, Tom

 

Remove the C-pillar trim panel. For additional information, refer to C-Pillar Trim Panel in this section.
Remove the door scuff plate.
Position aside the rear door opening weatherstrip.

Remove the trim panel clip.

Vehicles without third row seat


If equipped, remove the luggage assembly cover.

Remove the stowage compartment doors.

NOTE: Right side shown, left side similar.

Remove the stowage compartment assembly.

Position the carpet aside.

Remove the brackets.
Remove the bolts.

Vehicles with third row seat


Remove the third row seat. For additional information, refer to Section 501-10.
All vehicles


Remove the D-pillar trim panel. For additional information, refer to D-Pillar Trim Panel in this section.

Disconnect the power door lock electrical connector.

Remove the liftgate door scuff plate.

Remove the rear quarter trim panel.

To install, reverse the removal procedure.

And since you will likely ask about the C pillar

C-Pillar Trim Panel
Removal and Installation

All vehicles


Lower the rear door opening weatherstrip.

Remove the trim panel clips.

Vehicles with third row seats


Position the second row outer seats to the forward position.
Vehicles without third row seats


Remove the rear seats. For additional information, refer to Section 501-10.
All vehicles


Remove the lower safety belt anchor bolt.

Remove the trim panel.
Pull the lower portion of the trim panel outward to release the lower tab.
Pull trim panel downward to release upper tabs. Remove the trim panel.

To install, reverse the removal procedure.

And Since you will likely ask about the D pillar

D-Pillar Trim Panel
Removal and Installation

Vehicles with third row seat


Remove the third row seat cushion. For additional information, refer to Section 501-10.
Remove the safety belt anchor bolt for the third seat strap.

All vehicles


Remove the liftgate opening weatherstrip.

Remove the rear upper headliner trim panel.

Remove the D-pillar trim panel.

NOTE: Make sure that the quarter glass attachments are correctly seated at the beginning of the installation procedure.

To install, reverse the removal procedure.

 

These instructions for removing the rear trim panels were very helpful. I have exposed the rear climate control housing assembly, but am trying to figure out which bolts to remove so as to get to the blend door and actuator. There is a panel on the left top of the assembly held down by six small screws but I am unsure whether they need to be removed. I also found a larger bolt above the middle of the assembly apparently securing it to the side of the Explorer. Would appreciate advice on what further bolts I have to remove. Thanks a lot.

 

Dont know what year you have edmike, but if you have a late model it should only be 3 bolts and a nut securing the whole assembly to the side. remove or move out of the way the air duct and remove those securing bolts and then just pull the assembly far enough from the quarter panel to access the actuators. The one closest to the rear of the vehicle is for blend door. The other is for roof vent/floor vent control.

 

Dear Homer: I removed two bolts and a nut on my 2002 Explorer and successfully accessed and removed the two actuators. My only question now is whether I should replace both or just the blend door actuator, which seems to have been the one with the problem. I'm leaning toward both, so I don't have to do this job again for a looong time. What do you think? Thanks very much, Ed.

 

You can do what ever you feel safe with, but I have only seen the blend door actuator bad on the Explorer to date. I did have one bad vent door actuator on an expedition but only one.