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The subject of broken blend doors comes up on a somewhat regular basis in this forum. Since this seems to be a common problem, is there something that the pro-active owner should do as regular maintanence that would prevent failure or certainly delay failure? Inquiring minds need to know.
I don't think that there is much you can do. The hot and cold takes it's toll on plastic over the years. I often switch my controls just to keep the stuff moving and free. Sometimes if they stay in the same position for a long time, they stick and then when you finally move them, the added force needed to unstick them, breaks the plastic.
Just switch from cold to hot and back once a week to help keep it moving would be about the only preventive maintenance that I could think of.
By the way, What part of Louisville are you in? I'm in the PRP area.
If the cycling of temperatures is causing the plastic to deteriorate, then IMHO Ford has chosen a plastic for this part that has the wrong physical properties. Is there an aftermarket replacement part that is more durable? I have never seen what a blend door looks like. Is there a picture of one somewhere that you know of?
My truck has EATC which means that the blend door is adjusted automatically as needed by the temperature setting. I can change temps from one extreme to the other to accomplish your recommendation.
I am in the Okolona area, near Jefferson Mall and work in Bluegrass Industrial Park.