My girlfriend has a 2002 Exploder. The door that controls the air distribution is not working properly.

I dropped the glove box and behind the HVAC controls is a lever that goes into the air box. I touched this lever and heard something drop inside. I was able to get the arm to snap in but it pops out.

I heard to fix this the correct way, the whole dask needs to be removed to split the air box. I was wondering if a hole could be cut into the box and repair whatever is inside is possible? Has anyone dealt with this air diverter door?

Thanks

Billy T.
gnxtc2@aol.com

 

lets figure out what door your looking at. There is a "blend door" that mixes hot and cold air to control the temp you want... THere is a "fresh air" door just behind the glove box. If you take out the glove box you will see the door aginst the fire wall, behind a plastic grill. The door is normally suppose to be toward the glove box and lets outside air into the air duct. When you swith to "max AC" the door goes forward and closes off outside air and recircs the inside air to make it colder. Noramlly you first notice you have troubel with the "recir door" when you are leaking cold air onto the passenger side floor in the winter. I had the control arm break. Decided to do "fix" in place. i pushed the door forward with a small square stick that has a notch on it. Push it forward and put the notch aginst the plastic grill. Door is permanently "closed" for outside air.

What is your "not working properly" symptom ?

 

The problem is that the air is not being distributed correctly. When the control **** is on max AC, it's coming out of the defrost.

When I dropped the glove door, there is a vacuum operated lever on the of the right side of the air box that's behind the center of the dash. When I turn the selector **** is turned to various levels, the lever works. The lever is connected to a shaft that goes into the air box.

I have no issues with the blend or re-circ doors

Billy T.
gnxtc2@aol.com

 

On my 04' Explorer,,I had the issue with the fresh air door,,,it had completly fallen off it's pivot mounts,,,and was laying on top of the Blower motor screen,,blocking approx 75% of the air movement !,,,I removed the 6- or so bolts,,that mounts the cage to the blower,,,still not enough room to get my hand in,,,(remember the door or something was blocking the air movement),,so I grabbed my sharp(new blade) Utility Knife,,,was able to slit the 2 corners of the cage,,,then that flap would pivot enough to get my hand in,,,,,pulled the whole door right out,,,,plus found a mouse nest of firewall insulation ontop of the blower screen,,,,pulled all that trash out,,,,ahhh nice air flo again,,,,slid the air door back up inside,,put in its correct posistion,,,and screwed it shut,,,with a Dewalt drill,,,6" extension and 4- 1-1/4 Drywall screws,,,never to open or let mice in again,,,,AC blows cold,,,,all works well!! What the hell kind of design is it,,,, that just falls apart with only 30k miles or so on the vehicle !!,,,Get a clue FORD design team!!,,Plus I have heard of Ford Taurus's with many heater issues,,,,DON'T MAKE STUFF SO COMPLICATED!!!

These Electronic Climate Control,,,what a joke,,,your in a car or truck,,,what maybe 4' ft apart,,,,what the hell you need seperate controls for,,,,set it a a decent temp and drive,,,,a vent can be closed by hand,,,or the temp adjusted so one is comfy,,,,SIMPLE IS ALWAYS MORE RELIABLE!

 

im with you now Bill, that is the damper that directs air up to defrost or down to the floor. NOrmally it dont fail, thats an odd one. Normally you loose vacuum and the door dont work. Those doors are open- close, with vacuum, they dont regulate 10-20-30% open. Below is a diagram that shows how the things work. Sorry i cant tell you how to fix it, never done that.. On another note, when the blend door fails , some guys cut a 6 x 6 inch hole in the air duct so they can reach inside and reattach or rebuild the linkage. Then the RTV or sheetmetal screw the cover back on... maybe for you ???


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