Blend door replacement
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Junior User
Joined: Aug 2004
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Blend door replacement
I did the infamous blend door fix a couple of years ago. In the June RockAuto newsletter, they feature a replacement blend door available from Dorman that gets installed by cutting away thebottom of the airbox. Anyone here tried it yet?
Elder User
Joined: May 2004
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From: Webster, NY
ayup, could not do the "usual" fix on mine due to too much damage. I bought a replacement door at NAPA and put it in. Since I already had a hole in the side of the plenum (I would tape the door where I wanted it before it was fixed) it was easy. There is another thread (or two) on here about the door replacement.
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Joined: Dec 2000
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A couple of years ago I did the "quick fix" by putting a nail on the end of the actuator shaft but then the whole top piece of the door broke off. This past winter all I had was full heat because the door would slam shut to hot when you turned on the heater. That was OK when it was really cold but it would roast you out when you only needed alittle heat. I just did my Explorer with a the replacement door from Rock Auto. I cut the bottom triangle hole in the bottom of the heater box and I split the seam where the top and bottom pices of the box come together. The old door fell right out of the holes. I then just reversed what I did to put the new door in and it works like new now. I have to do my wife's Explorer next but I'm going to use the door from NAPA. It costs $11.00 plus tax. PS I unbolted the front passenger seat and let it tip back on the rear seat to give me more room to work with. It was worth the time for 4 bolts to have extra room as I'm a big guy. The NAPA number is BK660-1810
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Originally Posted by drifter
A couple of years ago I did the "quick fix" by putting a nail on the end of the actuator shaft but then the whole top piece of the door broke off. This past winter all I had was full heat because the door would slam shut to hot when you turned on the heater. That was OK when it was really cold but it would roast you out when you only needed alittle heat. I just did my Explorer with a the replacement door from Rock Auto. I cut the bottom triangle hole in the bottom of the heater box and I split the seam where the top and bottom pices of the box come together. The old door fell right out of the holes. I then just reversed what I did to put the new door in and it works like new now. I have to do my wife's Explorer next but I'm going to use the door from NAPA. It costs $11.00 plus tax. PS I unbolted the front passenger seat and let it tip back on the rear seat to give me more room to work with. It was worth the time for 4 bolts to have extra room as I'm a big guy. The NAPA number is BK660-1810
Senior User
Joined: Dec 2003
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Did the NAPA trip also bought the blend door itself part # BK6601810 the cost was $10.00 and labor sucks if you do it uself, i cut under the airbox where the door is and bingo the door comes out like a charm after some pulling and stuff, took me about 2 hours to do the complete job by removing the glove box, the passenger's airbag and some odds n ends that were in the way, i found it easier if the airbag was out so you can see straight down to the box. Good Luck!!! 
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JackTN
1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks
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Feb 8, 2017 07:02 AM
