2002 Ford Explorer 2002 XLT.
When turning the climate control from blue to red, there is a clicking sound (every second) underneath the middle console . Nothing but cold air is blowing out. I have spent a good hour trying to find the actuator to see if it is a blend door issue but can't be certain. I can't find the actuator or a Ford diagram to give me a clue.The fan does work properly. I have googled many different options and got one find called the LAST RESORT BLEND DOOR FIX, but I'm still not certain. Why would the clicking noise be coming from underneath the dash and middle console if it is the blend door issue?

 

When I look at the blend door fixes, and remove the glove box, I'm not seeing what is pictured. Is there anywhere else to find documentation or pictures of where the actuator would be on a 2002 Ford Explorer ?

 

I have the same year explorer and the same problem.I have found the same thing as far as the steps and pictures from the forums and like popsterthe, these do not match what I see when I drop the glove box.
Has anybody found anything to help on the 2002 blend door fix?I was told that the 2002 and 2003 are the same but no luck locating it like the pictures show for the late 1990's model.

In bad need of help with the temp getting in the teens

 

i have a 02 explorer last winter the same thing happened.the ford dealer said blend door was stuck he replaced it.the blend door is only plastic it wears after time.

 

do you know where the blend door is on the 2002?

 

if i remember right behind the glove box

 

I have found and fixed the actuator on my 2002 explorer. I found the actuator
behind the heater/ac control. The heater core and all is located here. You can find the actutor on the driver side of the black box in the center on dash. The center console has to be removed also.its a very tight fit but you can get to all three bolts for the actuator, you will need a 8 mm wrench to get these out. I found it helped when I took some of the bolts that holds the middle of the dash .


Good luck

 

can you list this in 10 steps on waht you did? how long did it take? did you replace the door or repair?

 

#1 pulled trim piece around radio and heater/Ac control ( unplugged heater/ac control)
#2 pulled center console out ( dont forget to remove to screws from back corner of console, you will have to pop off the corner plastic pieces to see these screws)
#3 removed the bottom part of dash under steering wheel ( 2 screws)
#4 removed metal dash support ( piece that goes from floor to dash behind the consloe, two nuts from floor and two bolts from dash)
#5 pulled the floor vent duck work from driving side ( 2 screws )
#6 removed several screws form dash in middle so it would move a little ( you may not have to do this but I did just trying to make it easier to get to the actuator)
#7 pulled the actuator ( 3 screws) and unplugged)
the top screw on top back corner is rough to get to .

you will need a 1/4 inch ratchet with a 7 and 8 MM socket, I also used a three inch extension on some of the screws.
you will also have to have a 8mm wrench to remove the actuator.


I replaced my actuator, it was not turning at all,appeared that the gear inside was gone.
You do not have to get this from the dealer. Advanced Auto ordered one for me. I had it the next day.I paid 49.88. I also found that a Hanyes manual was helpful also ( 18.00)Make sure you get the manual for the correct year you have. I was told that the 2002 and 2003 where the same. The manual I bought was for both years.The wording was not helpful ( as far as locating the front actuator but looking at the pictures helped alot.

I worked on and off on this a couple of days ( took some things apart that was not needed, I was trying to use the steps someone had told me about for a late 90's model, they are notset up the same way.
Once I figured out what had to be done I figure I had a couple of hours in on this.
You could make it easier to get to the actuator if you pullled the complete heater box off but this requires more things to take off ( to do this you would have to unhook and pull the heater core out0


Goodluck

 

Thank you for the detailed procedure. I am thinking about trying this myself, but I am concerned that this repair may be out of my league. Is this something that a novice handyman could sucessfully complete?

Any idea how much a repair shop would charge for this?? Thanks for the help...